Advanced Process Engineer (Metal AM)

At an established AM shop, a process engineer runs existing parameter sets on certified machine platforms. The alloys are qualified, the windows are defined, and the job is yield and cycle time. The interesting decisions were made before you arrived.

• →Design and execute DOEs for hard-to-print metal alloys on production LPBF machines - and document what you learn
• →Develop process parameters from scratch for extreme-preheat platforms printing crack-prone superalloys
• →Own part-specific application development: build orientation, support strategy, distortion compensation, depowdering, heat treat and HIP specification, machining interfaces, and inspection plans
• →Automate the work: programmatic DOE generation and build prep to minimize manual work and set up files in a fraction of the normal time
• →Write the documentation that carries the process from R&D to production: procedures, work instructions, build records, powder reuse tracking, traceability
• →Help scope, procure, install, and commission equipment - then use it and train others on it
• →Work shoulder-to-shoulder with technicians and M&P engineers - everyone in this lab builds, documents, and troubleshoots

The manufacturing process you need won't exist yet - you'll develop it. Many of these alloys are notoriously difficult to print and the machines we're bringing in are at the frontier of what the industry has qualified. The parts you print will run in an engine, which means your process rigor, approach to quality, and documentation discipline have to be absolute. If a result is uncertain, we need to know that more than we need it to look ready.

• A Bachelor's, Master's, or PhD in engineering with a focus on materials, manufacturing, or additive manufacturing
• 5+ years of experience in LPBF process and/or applications development on real programs, with real customers and real consequences (we're hiring across a range of levels - exceptional depth can substitute for years)
• Hands-on LPBF experience: you have personally loaded powder, set up builds, monitored them, and debugged failure modes - not just prepared files
• Process development ownership: parameters you developed, DOEs you designed, failure modes you diagnosed and closed
• Working knowledge of build-prep software, such as: Dyndrite, Magics, 3DXpert, EOSPrint, Netfabb, or similar
• Programming experience - Python preferred - and the instinct to automate anything you've done twice
• Documentation and traceability habits that would survive a quality audit

• Experience with high-temperature, crack-prone nickel superalloys - high gamma prime alloys
• Experience on high-preheat LPBF platforms or with reactive metal alloys
• Materials evaluation experience: metallography, SEM, tensile/fatigue/creep testing, fractography, powder characterization
• Exposure to qualification programs: allowables thinking, MMPDS/CMH-17 concepts, statistical treatment of material data
• Experience carrying a process from R&D into production in a regulated environment (AS9100 or similar)
• Startup or prototype-pace experience - comfort in a lab where the process doesn't exist yet and priorities shift fast

Superpower is the first industrial turbine purpose-built for AI data center loads, targeting a market growing faster than the grid can serve it - and its core is shared with Symphony, the engine that brings back supersonic passenger flight. The AM capability you build here determines whether the hardest parts in the engine arrive on schedule - parts nobody else knows how to print. The machines are the most advanced in the world, the alloys are the hardest in the industry, and the parts go into real engines. There is no equivalent seat anywhere.

To conform to U.S. Government aerospace technology export regulations (ITAR and EAR), applicant must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State. Learn more about ITAR here.

Boom is an equal opportunity employer, including for individuals with disabilities and protected veterans. We are building a culture of merit and excellence.

Want to build a faster future? Come join Boom.