Senior Manufacturing Process Development Engineer - Medical
Confirmed on the employer's own hiring board on Oct 28, 2026. First seen by Alion on Jul 21, 2026. VulcanForms scores A on the Alion truth index.
About Us
Founded in 2015 to develop the world’s first industrially scalable laser metal additive manufacturing solution, VulcanForms is reshaping how the world manufactures critical products. We build and operate advanced digital infrastructure that enables innovation, accelerates growth, and supports sustainability across aerospace, defense, medical, and other essential industries. Through our vertically integrated capabilities, including scalable additive manufacturing and precision machining, we deliver true end-to-end production at scale by combining cutting-edge technology with a foundation of proven industrial craftsmanship. Our team brings deep expertise in manufacturing, materials science, software, automation, and operations, united by a shared commitment to quality, curiosity, and accountability. We foster an inclusive culture where people take ownership, solve meaningful problems, and continuously learn, because we believe diverse perspectives lead to better outcomes.
Job Purpose
The Senior Manufacturing Process Development Engineer will establish and optimize reliable processes, working cross-functionally to deliver safe, efficient processes that meet quality, cost, capacity, and customer requirements within our Medical business unit. This role will work cross-functionally on NPI teams to support process development and help successfully sample and launch new products. This role will also be responsible for taking new products from post-print to finished product by developing and scaling robust post-processing operations. They will provide technical leadership for the Production Team, define process requirements, coordinate with suppliers, and implement tooling and equipment solutions for post-processing printed parts and components.
Key Responsibilities
- Define and support post-processing steps (e.g., machining, blasting, deburring, cleaning, heat treating) for newproduct; turn product designs and requirements into robust, scalable manufacturing processes.
- Oversee the implementation of manufacturing processes by collaborating with in-house technicians and external suppliers. Coordinate machine setup and process validation whilemaintainingtechnical ownership.
- Define functional requirements for tooling, fixturing, and post-processing equipment, including identifying opportunities for automation or capital investment to improve productivity. Partner with suppliers to deliver reliable solutions, and lead their implementation, testing, and validation.
- Write andmaintaindetailed work instructions, standard operating procedures (SOPs), and process documentation to ensure repeatable and high-quality production.
- Lead Installation Qualifications (IQ) for manufacturing equipment and support QC and Quality Engineering in Operational and Performance Qualifications (OQ/PQ). Help ensure all processes meet quality and regulatory requirements.
- Engage in the NPI processasrequiredto understand part requirements and contribute to design-for-manufacturability (DFM) decisions. Work closely with design, quality, and production teams toalign oncost, capability, and scalability.
- Collaborate with product and manufacturing teams to define takt time, throughput targets, and resource needs (equipment, labor, space) to support forecasted production volumes - including estimating manufacturing costs and time standards for new and existing products.
- Work with the HSSE team to assess risks and ensure that new equipment and processes meet internal safety and ergonomic standards.
- Drive process improvements aimed at scrap reduction and cost savings using root cause analysis, leantoolsand data-driven decision making.
Qualifications
- Bachelor’s degree in Mechanical, Manufacturing, or Industrial Engineering (or related field)
- 5+ years of experience in manufacturing engineering, with a focus on post-processing methods (e.g., machining, blasting, fixturing)
- Hands-on experience developing and scaling production processes
- Proficiencyin process qualification tools and methods (e.g., PFMEA, DOE, IQ/OQ/PQ)
- Strong cross-functional collaboration skills, including working with suppliers, technicians, and internal engineering, quality, and production teams
- Experiencecreating andmaintainingprocess documentation (e.g., SOPs, work instructions, validation plans)
- Knowledge of Lean Manufacturing, root cause analysis, and continuous improvement methods
Preferred Qualifications
- Experience with metal additive manufacturing and transitioning printed parts to finished product
- Familiarity with post-processing techniques, GD&T, and tooling design (hands-on or oversight)
- Background in regulated or quality-controlled environments (e.g., medical device, aerospace) and experience qualifying equipment or automated processes
- Exposure to ERP/MES systems, manufacturing data tools, and safety or ergonomic assessments
VulcanForms offers a competitive salary and equity package. Actual compensation is based on factors such as the candidate's skills, qualifications, and experience. In addition, VulcanForms provides comprehensive benefits including medical, dental, vision, and life insurance; generous paid time off; and a 401(k) plan with company match.
The annual base salary range for this position is $106,500 to $146,000.