Commissioning Technician III

The Commissioning Technician III is responsible for commissioning, calibration, troubleshooting, repair, rework, and qualification of large-format laser powder bed fusion (LPBF) 3D printers and supporting manufacturing equipment.

The role brings complex equipment and integrated systems online, verifies performance against engineering requirements, restores non-conforming equipment to full capability, and prepares equipment for production operation.

The Technician is specifically responsible for multi-laser optical calibration and verification, including laser alignment and registration to the machine coordinate system and build plane. The role also supports mechanical, electrical, motion, pneumatic, hydraulic, controls, robotics, powder-handling, inert-gas, and other systems as applicable.

• Commission LPBF printers and supporting manufacturing equipment following assembly, installation, or major modification.
• Bring equipment and subsystems online in a controlled sequence and verify performance against engineering requirements.
• Commission LPBF systems including X/Y/Z motion, powder handling, inert gas, condensate collection, controls, recoater systems, and multi-laser optical systems.
• Verify system interfaces, machine configuration, and conditions required for calibration and qualification.
• Identify conditions affecting accuracy, repeatability, throughput, quality, or production readiness.

• Commission X/Y/Z motion stages and verify positioning, homing, travel limits, alignment, and repeatability.
• Commission powder handling, inert gas, condensate collection, and associated control systems.
• Bring hardware controls online and verify communications, I/O, sensors, actuators, alarms, and interlocks.
• Install, align, adjust, and verify recoater systems.

• Perform and document optical calibration of multi-laser LPBF systems in accordance with engineering requirements.
• Align and register each laser to the machine coordinate system and common build plane.
• Verify laser-to-laser alignment, positioning, and optical performance across the build area.
• Use optical measurement and calibration equipment to identify and correct alignment or performance issues.
• Perform approved optical adjustments, calibration, and related mechanical rework.
• Troubleshoot optical issues and work with Engineering on conditions outside established procedures.
• Repeat calibration following repairs, component changes, or other modifications affecting optical performance.
• Maintain calibration records and confirm optical acceptance criteria before machine qualification.

• Commission depowdering equipment and verify material removal, containment, collection, controls, and safety systems.
• Commission powder sieving and handling systems and verify material flow, transfer, controls, and interfaces.
• Commission anodizing and coating lines and associated material handling, fluid systems, controls, and safety systems.
• Commission robotic assembly cells, including robots, tooling, fixtures, sensors, safety systems, and programmed sequences.
• Commission automated material-handling systems supporting LPBF production.

• Commission and verify precision motion systems using established procedures and engineering requirements.
• Establish and verify machine coordinate systems, homing, travel limits, positioning, and motion performance.
• Perform mechanical alignment, calibration, adjustment, and verification using precision measurement equipment.
• Troubleshoot motion issues involving mechanical components, sensors, motors, drives, encoders, controls, and configuration.
• Document calibration results and escalate conditions requiring Engineering support.

• Commission controls including sensors, actuators, drives, valves, motors, robots, and interlocks.
• Verify I/O, communications, machine states, alarms, safety systems, and interlocks.
• Execute functional checks and verify commanded versus actual equipment response.
• Troubleshoot automation issues using equipment behavior, measurements, diagnostics, and system information.
• Verify robotic sequences, automated cycles, material handling, and equipment interfaces.
• Work with Controls, Software, Robotics, and Development Engineering to resolve system-level issues.

• Perform repairs, rework, adjustments, replacements, and corrective actions required to bring equipment into specification.
• Diagnose non-functioning or underperforming equipment and determine the appropriate repair, rework, or escalation path.
• Troubleshoot mechanical, electrical, pneumatic, hydraulic, motion, controls, robotic, optical, powder-handling, fluid, and gas systems.
• Use drawings, specifications, test data, configuration information, and diagnostics to identify sources of non-conformance.
• Verify repaired or reworked equipment meets functional, calibration, safety, and performance requirements.
• Document repairs, rework, component changes, and verification results.
• Own commissioning issues through identification, corrective action, and verification.

• Execute equipment test cycles, process runs, and qualification activities following commissioning and calibration.
• Execute LPBF test prints to verify alignment, calibration, functionality, and production readiness.
• Verify critical commissioning gates, including optical calibration, laser registration, motion calibration, and recoater alignment, before qualification builds.
• Prepare machines for qualification by verifying configuration, calibration, consumables, process parameters, and safety conditions.
• Execute verification activities for depowdering, sieving, coating, anodizing, robotic assembly, and other supporting equipment.
• Evaluate machine and process data against engineering requirements and acceptance criteria.
• Perform follow-up measurements, adjustments, repairs, or rework as required.
• Document test and qualification results and support final equipment acceptance.

• Ability to lawfully access information and technology that is subject to US export controls.
• 5+ years of experience in equipment commissioning, machine integration, electromechanical assembly, manufacturing, testing, automation, robotics, or a related technical field; equivalent experience may be considered.
• Demonstrated ability to troubleshoot complex mechanical and electromechanical equipment.
• Ability to interpret engineering drawings, schematics, specifications, procedures, and technical documentation.
• Working knowledge of motion systems, motors, drives, sensors, actuators, and industrial controls.
• Experience using mechanical and electrical measurement equipment.
• Experience with commissioning, calibration, verification, and structured troubleshooting.
• Ability to recognize conditions that do not conform to engineering requirements.
• Experience using ERP, MRP, MES, or similar manufacturing systems.
• Strong technical documentation and communication skills.
• Ability to work independently while collaborating with a multidisciplinary team.

• Experience commissioning industrial 3D printers, additive manufacturing equipment, or complex capital equipment.
• Experience with LPBF systems and multi-laser optical calibration or alignment.
• Experience with depowdering, powder sieving, powder handling, coating, anodizing, robotic assembly, or automated material handling.
• Experience with precision motion systems, servo systems, encoders, motors, and drives.
• Experience with pneumatic, hydraulic, inert-gas, vacuum, fluid, or powder-handling systems.
• Experience with PLCs, industrial controls, robotics, sensors, actuators, and automated equipment.
• Experience with machine qualification, acceptance testing, or production release.
• Experience with precision alignment, calibration, GD&T, and dimensional measurement.
• Experience in aerospace, automotive, robotics, semiconductor, additive manufacturing, or other advanced manufacturing environments.
• Experience developing standardized processes or applying Lean/continuous-improvement methods.

• Use ERP and manufacturing systems to record commissioning work orders, equipment status, material consumption, and completed operations.
• Maintain equipment configuration, serialized hardware, component revision, calibration, and commissioning records.
• Document as-built configuration and approved changes made during commissioning.
• Complete commissioning, inspection, calibration, and qualification records while maintaining traceability of repairs, rework, component changes, optical calibration, and configuration updates.

• Identify sources of commissioning delay, rework, variability, and recurring failures.
• Develop and implement improvements to commissioning sequences, procedures, tooling, fixtures, calibration methods, and test methods.
• Improve optical calibration methods while maintaining required accuracy and repeatability.
• Use commissioning data, failure history, and team feedback to identify improvement opportunities.
• Standardize effective commissioning methods across equipment and manufacturing cells.
• Capture lessons learned and incorporate improvements into procedures, standard work, training, and troubleshooting guides.

• Work collaboratively with technicians of varying skill levels to complete commissioning, troubleshooting, repair, rework, and qualification activities.
• Provide technical assistance and knowledge transfer to less-experienced technicians and seek support when required.
• Share troubleshooting methods, equipment knowledge, and lessons learned.
• Communicate equipment status, technical issues, risks, and required support clearly.
• Work closely with Engineering, Manufacturing Engineering, Controls, Software, Quality, Supply Chain, and Operations.