LBF Process Design Engineer
New Today
Position Title: LPBF Process Design Engineer
Location: Indianapolis, IN
Our client is a leading manufacturer of additive machines specializing in metal 3D printing. They are seeking a LPBF Process Design Engineer to join their growing team. As a Process Design Engineer, you will drive the development and optimization of subsystems and process signatures across their LPBF platforms. You will translate thermal-fluid dynamics into robust, scalable manufacturing processes, collaborating with machine engineers and quality teams to accelerate product quality and performance. This role blends hands-on experimentation and computer-based modeling and analysis.
Key Responsibilities
Process Characterization & Signatures
- Design and execute experiments to map thermal, optical, and fluidic signatures of LPBF subsystems (e.g., powder delivery, melt pool dynamics, gas flow, scanner timing, laser intensity profiles)
- Develop and integrate sensor setups for real-time signature capture and feedback control
CFD & Simulation Modeling
- Develop and validate CFD models for melt-pool dynamics in Flow3D.
- Perform parametric studies and sensitivity analyses to guide process design.
Material Testing Coordination
- Plan and manage experimental campaigns with commercial testing laboratories and university research labs for powder characterization, CT scanning, microstructure evaluation, and mechanical testing.
- Coordinate sample preparation, test method selection, and data integration to support process design decisions.
Data Analysis & Visualization
- Build data pipelines and dashboards in Python (or similar) for visualization of process variables, test results, and simulation outputs.
- Use statistical tools (DOE, regression analysis) to identify key process drivers and optimize parameters.
Process Optimization & Scale-Up
- Apply root-cause analysis and DOE methodologies to improve part quality, yield, and reproducibility
- Support technology transfer activities, guiding scale-up from R&D to pilot and production systems
Cross-Functional Collaboration
- Work closely with R&D, machine design, and quality systems to embed process insights into product requirements
- Engage with universities and subcontractors to leverage external expertise and resources throughout process design and testing
Documentation & Quality Support
- Draft process design reports, technical presentations, and quality protocols (e.g., AS9100, ASTM standards)
- Contribute to internal quality frameworks (PAQ) and support customer audits or DoD submissions
Required Qualifications
- Bachelor's or Master's degree in Mechanical Engineering, Materials Science, or related field
- 3+ years of experience in process development, or additive manufacturing
- Experience or familiarity in Python or other coding languages for data visualization and analysis
- Demonstrated ability to design experiments, analyze complex datasets, and distill actionable insights
- Strong time management skills, with ability to coordinate multi-site or cross-disciplinary campaigns
- Excellent written and verbal communication skills for technical and non-technical audiences
Preferred Qualifications
- Direct experience with LPBF systems and metallurgy
- Experience with machine-process integration, sensor data acquisition, or control system design
- Proficiency with CFD software (ANSYS Fluent, STAR-CCM+, or similar) and data analysis tools (Python, MATLAB)
- Familiarity with design of experiments (DOE) and statistical analysis (Minitab, JMP)
- Knowledge of quality management standards (AS9100, ISO 9001) and regulatory requirements (ITAR, DoD procurement)
If you're interested in learning more about this opportunity, please send your resume to [email protected].
- Location:
- Indianapolis