Job Description:
The Senior Process Engineer – Metal Binder Jetting (MBJ) leads the development, optimization, and industrialization of binder jet additive manufacturing processes across the full production chain (printing, curing, depowdering, and sintering). This role is responsible for process performance, material outcomes, and production scalability, ensuring consistent material properties, dimensional accuracy, and cost-effective manufacturing, with a strong focus on sinter-based metallurgy (e.g., copper and advanced alloys).
The position involves hands-on engineering on the production floor, working directly with AM equipment, post-processing systems, and furnaces and plays a key role in bridging engineering and operations to enable successful process implementation, scale-up, and continuous improvement.
Working cross-functionally with operations, quality, and global engineering teams, this role supports new product introduction (NPI), process transfer, and production stability. The Senior Process Engineer operates with a high degree of technical independence, provides mentorship, and serves as a technical leader in advancing MBJ capabilities.
Experience with Metal Binder Jetting is preferred; experience with sintering-based processes (e.g., MIM, powder metallurgy) is highly beneficial.
Responsibilities
- Lead development and optimization of binder jetting process parameters across the full production chain (print → cure → depowder → sinter), including hands-on troubleshooting on printers, depowdering systems, and furnaces
- Drive improvements in green density, shrinkage control, distortion mitigation, and overall sintering performance through particle size distribution, chemistry, and binder removal optimization
- Own process validation, qualification, and capability studies for new materials and components, and transfer validated processes into stable, repeatable production environments
- Support and lead production development activities, including equipment setup, parameter tuning, process scaling, and standardization of work instructions and training programs
- Troubleshoot and resolve defects such as porosity, cracking, distortion, and density variation using root cause analysis and advanced technical problem-solving
- Lead DFAM, feasibility assessments, and development of scalable design guidelines, including CAD preparation, build layouts, and process strategies
- Develop and standardize design guidelines for scalable MBJ production
- Drive measurable improvements in yield, cost, throughput, and overall process capability through continuous improvement initiatives
- Collaborate with internal teams, external partners, and equipment suppliers (e.g., HP Inc.), and interface with customers on technical feasibility and application development
Qualifications
- Bachelor’s or Master’s degree in Mechanical, Materials, Manufacturing Engineering, or related field
- 5–10+ years of experience in additive manufacturing, powder metallurgy, or sintering-based processes
- Proven experience in hands-on process development and production support
- Experience with Metal Binder Jetting strongly preferred
- Advanced knowledge of sintering and thermal processing
- Strong understanding of powder behavior, metallurgy, and material science
- Expertise in dimensional control, shrinkage, and distortion management
- Strong background in DOE, process validation, and root cause analysis
- Experience scaling processes from development to production
- Familiarity with quality systems (ISO/IATF preferred)