Senior Manufacturing Process Development Engineer - Consumer Technology
Confirmed on the employer's own hiring board on Oct 27, 2026. First seen by Alion on Jun 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 Manufacturing Process Development Engineer, Consumer you will own the end-to-end technical framework that translates customer designs into repeatable, high-performance physical products within our consumer-technology business. You will bridge the gap between material science and high-volume digital production, overseeing the comprehensive process pipeline-including laser parameter optimization, print layouts, and post-printing thermal treatments. Success in this role means establishing stable, optimized processing windows that guarantee the mechanical, aesthetic, and metallurgical integrity of parts coming off our advanced production lines.
Key Responsibilities
- End-to-End Process Ownership: Define, document, and optimize the comprehensive 3D digital manufacturing workflow, owning process intent from initial laser print files through stress-relief, heat treatment, and final part extraction.
- Recipe & Parameter Development: Pioneer and refine high-temperature thermal recipes, laser interaction parameters, and advanced printing strategies to meet strict mechanical properties, surface finish requirements, and microstructural tolerances.
- Data-Driven Optimization: Design and execute complex Design of Experiments (DOE) using statistical software (such as Minitab or JMP) to analyze process capability, drive continuous yield improvements, and minimize scrap rates.
- Defect & Root Cause Analysis: Lead technical investigations into failed builds, non-conformances, geometric distortions, and metallurgical variations, implementing robust corrective and preventive actions (CAPA).
- DFAM Partnership: Collaborate with Applications and Design teams on Design for Additive Manufacturing (DFAM) reviews, evaluating customer CAD geometries, support structures, and post-processing constraints to ensure stable manufacturability.
Qualifications
- Experience: 5+ years of experience in process development, metallurgical engineering, or advanced materials processing within high-precision manufacturing (such as Metal Additive Manufacturing, Semiconductor fabrication, Aerospace processing, or advanced Injection Molding).
- Statistical Rigor: Proven ability to build and analyze statistical process control (SPC) data and DOEs to establish highly repeatable manufacturing windows.
- Materials Literacy: Deep understanding of material behavior, thermal stress development, microstructural evolution, or mechanical testing protocols.
- Education: Bachelor’s or Master’s degree in Materials Science, Metallurgical Engineering, Mechanical Engineering, Chemical Engineering, or a related technical discipline.
- Soft Skills: Analytical, structured problem solver with excellent cross-functional communication skills to translate complex processing data into actionable engineering workflows.
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 $106,000 to $146,000.