Senior Process Engineer, Post Processing - Aerospace & Defense
Confirmed on the employer's own hiring board on Oct 28, 2026. First seen by Alion on Aug 10, 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
As a Senior Process Engineer, Post-Processing at VulcanForms, you will design and direct the manufacturing processes that take our printed parts from the build plate to a finished, inspected product. You will work on new product introduction and on continuous improvement of parts already in production, using advanced manufacturing techniques, automation, and lean manufacturing methods to develop an optimized production part.
You will define the processes, procedures, work instructions, and systems that produce our components and sub-assemblies to customer specification, drawing on product design, fabrication, assembly, work-holding, cutting tools, and materials expertise. You will support a wide range of aerospace and defense products.
Key Responsibilities
- Evaluate customer designs and provide Design for Additive Manufacturing (DFAM) feedback.
- Partner with the rest of the product team to make sure processing intent is optimized for customer requirements.
- Own process development for every operation after printing, including part movement, depowdering, plate removal, heat treatment and subcontracted operations.
- Work with quality resources to ensure appropriate inspection techniques are employed, and are meeting customer needs in both a development, and production context.
- Encode internal and external customer requirements into the factory's manufacturing steps by building part-specific methods of manufacture in our ERP system.
- Design, develop, and implement fixtures and work-holding for process and part-handling steps such as depowdering, EDM, heat treatment, support removal, machining, assembly, cleaning, marking, and finishing -including prototype fixtures, whose manufacture you will oversee.
- Write and maintain work instructions and process-related quality documentation, adapting existing processes for new products and keeping files, programs, and revisions under proper configuration control.
- Keep parts moving through the factory by reviewing and dispositioning non-conforming material.
- Support operations with troubleshooting and problem-solving across every process step between printing and final delivery.
Qualifications
- 5+ years of progressive, hands-on experience in product or applications development or manufacturing environment.
- Bachelor's degree in Mechanical, Materials, Aerospace, Biomedical Engineering, or a similarly regulated field. AS9100 experience preferred.
- Proficiency in advanced 3D CAD software (e.g., Siemens NX, Creo, SolidWorks).
- Experience using ERP systems in a batch manufacturing process.
- Deep mastery of GD&T, advanced statistical process capability, tolerance stack-up analysis, and complex DFM/DfAM constraints.
- Strong working knowledge of subtractive manufacturing operations (5-axis milling, turning, EDM) and their integration with additive workflows (Depowdering, build plate resurfacing,etc).
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 ran