Senior Process Engineer, Additive Manufacturing
Confirmed on the employer's own hiring board on Nov 4, 2026. First seen by Alion on Nov 2, 2026.
About the Role
We’re looking for an industry-experienced, hands-on senior engineer with direct metal additive manufacturing experience - someone who has qualified materials and processes, troubleshot builds, analyzed failures and test results, and turned technical findings into reliable production solutions.
You’ll own our metallurgical test lab, lead material and process qualifications across multiple alloy systems, and work directly with AM equipment, materials, engineering, quality, and production to solve technical challenges and establish robust manufacturing processes.
What You'll Do
Build and operate our metallurgical test lab. Take our internal test lab from concept to day-to-day operation. You’ll help select and qualify equipment, establish test methods and procedures, develop calibration and maintenance requirements, and train others to use the equipment correctly. Capabilities will include particle size distribution, porosity characterization, mechanical testing, and microstructural analysis.
Lead hands-on material and process qualification. Develop and execute qualifications for stainless steel, nickel, titanium, aluminum, and other alloy systems. You’ll work directly with AM processes and equipment to establish parameters, run trials, evaluate results, and qualify processes to customer and industry requirements, including AMS, ASTM, and SAE standards.
Troubleshoot real manufacturing problems. When a build, material, or test result doesn’t meet expectations, you’ll help determine why. You’ll use metallurgical analysis, process data, structured experimentation, and hands-on investigation to identify root causes and implement practical corrective actions.
Own qualification from planning through execution. Lead IQ/OQ/PQ activities, DOE-based studies, process-window development, validation testing, documentation, and technical reporting. You’ll manage multiple qualification efforts and be accountable for driving them through completion.
Partner directly with manufacturing. Work closely with engineering, quality, and production to translate metallurgical requirements into processes that work on the shop floor. You’ll help establish build and validation documentation in ProShop ERP and develop practical training for the team.
Advance our AM capabilities. Identify better ways to qualify materials, validate processes, evaluate results, and solve emerging technical challenges as Rennscot’s additive manufacturing business grows.
What We're Looking For
We are open to a range of educational backgrounds - what matters most is what you have done and the impact you have made.
12+ years (H.S. Diploma) | 10+ years (A.A.) | 5+ years (Bachelor's) | 3+ years (Master's) | Ph.D.
A bachelor's or master’s in metallurgical engineering, materials science, or a closely related field is preferred.
Direct, hands-on experience with metal additive manufacturing processes such as laser powder bed fusion, DED, or binder jetting
Experience developing, qualifying, or improving AM materials and manufacturing processes in an industrial environment
Practical experience troubleshooting AM builds, material issues, defects, or process variation
Hands-on metallurgical testing experience, including microstructural analysis, porosity, mechanical testing, and/or powder characterization
Experience working with stainless steel, nickel, titanium, aluminum, or similar alloy systems
Experience executing process or equipment qualification, including IQ/OQ/PQ or comparable validation methodologies
Working knowledge of AMS, ASTM, SAE, customer specifications, or similar manufacturing standards
Experience using DOE, statistical analysis, and process data to make manufacturing decisions
Ability to translate metallurgical principles - including solidification, phase transformations, microstructure, and defect formation - into practical process decisions
Experience documenting qualification activities, test results, technical findings, and recommendations that can withstand internal and customer review
· Experience standing up or operating a metallurgical lab, working in aerospace or another highly regulated manufacturing environment, and qualifying AM processes for production applications is strongly preferred.
Job Type: On-Site
Job Location: Woburn, MA. At this time, we are only considering applicants within a 100-mile radius. No relocation assistance provided.
About Rennscot MFG
Rennscot MFG, founded in 2017, started as a motorsports-focused shop in the aftermarket automotive industry. Now, they are a leading provider of advanced manufacturing services located in Woburn, MA. Rennscot MFG strives to be more than just a machine shop; they solve problems in innovative ways, using a suite of integrated services to fuel a passion for ideation. With a focus on diversifying into commercial and critical technology sectors, Rennscot MFG delivers cutting-edge technologies and unwavering commitment to quality. They offer a comprehensive range of services, including reverse engineering, metal & polymer additive manufacturing, and precision machining to support various industries’ needs. For more information, visit rennscotmfg.com.
ITAR Requirement
To conform to US Government export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a US citizen, lawful permanent resident of the US, protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the US Department of State. Learn more about the ITAR here: https://www.pmddtc.state.gov/ddtc_public/ddtc_public?id=ddtc_public_portal_itar_landing.
EEO Statement
Rennscot MFG is an Equal Opportunity Employer; employment with Rennscot MFG is governed on the basis of merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.
It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.