Job Location
Burlington, MA, USA
Process Engineer – LPBF Gas Flow

About us
Born out of MIT, VulcanForms is commercializing the first fully scalable industrial metal additive manufacturing (AM) solution. Building the world's most powerful and advanced metal AM system is the first step towards our vision of lights-out, highest quality metal AM mass production. We are a team of leading technology and operational experts with decades of experience in advanced manufacturing, materials, automation, and robotics. We continuously seek contributors who demonstrate outstanding integrity, intelligence, accountability, and a passion for learning. We celebrate diversity and are committed to creating an inclusive environment for all employees.

Job Purpose
VulcanForms is seeking a Process Engineer to join our Gas Flow Engineering Team at our Burlington, MA facility. The main objective will be to analyze and optimize the interactions between welding and the gas flow system to enable the manufacturing of the highest quality parts in our high-speed laser powder-bed fusion (LPBF) process. You will be part of the team to define and develop the gas flow system and roadmaps for the world's most productive and advanced metal AM systems. You will explain the details of the weld and meltpool process, define the requirements for the gas flow system, and help develop gas flow system concepts into products. You will collaborate with the process, simulation, flow, controls, and materials experts to continuously improve the gas flow system and the overall LPBF process configurations. Your work's primary result is to provide our customers with superior parts of the highest quality that meets their specifications.

Key Accountabilities
  • Gas flow and welding process innovation and R&D on VulcanForms' high-speed laser powder-bed fusion process enabling technological breakthroughs in additive manufacturing.
  • Understand the interactions between the laser processing byproducts, the gas flow system, and other LPBF systems.
  • Define the analysis, testing, and validation needed to improve gas flow system performance continuously.
  • Design, execute and analyze experimental trials for gas flow system development.
  • Act as a technical liaison between System Design and the Process team
  • Analyze and test gas flow system concepts.
  • Communicate decisions, results, and challenges with colleagues of varying technical backgrounds.
  • Actively participate in the system integration, machine building, commissioning, and gathering first-hand feedback on the performance of your designs.
  • Bachelor's degree with 3+ years of industrial experience in Mechanical, Aerospace Engineering, Materials Science, or equivalent fields
  • Deep understanding and experience in laser welding, LPBF, or other metal additive process
  • Understanding of meltpool behavior and laser processing byproducts (spatter, particulates, etc.)
  • Experience with spatter mitigation and laser powder interaction
  • Experience using Design Of Experiments (DOE) methods
  • Authorized to work within the U.S. without restrictions or sponsorship now or in the future (U.S. Citizen or lawful Permanent Resident of the U.S. (U.S. green card holder))
  • Strong sense of ownership
  • Experience with flow simulation tools (i.e., COMSOL, ANSYS FLUENT, or other) and ability to analyze simulation results
  • Experience with AM-related software (Magics, nTopology, etc.) and CAD software (Creo, Autodesk Inventor, etc.)
  • Experience with Design of Experiments (DOE) and process optimization, familiarity with Minitab or JMP
  • Familiarity with programming languages such as python and MATLAB
  • Practical knowledge of metallurgy of alloys, including steel, aluminum, titanium, and nickel alloys
  • Materials characterization experience (metallography, SEM, etc.)
  • Excited about taking on new challenges in the metal additive manufacturing industry and working in a fast-paced startup environment
  • Team player with excellent communication skills
  • Hands-on, practical "get-it-done" attitude
  • Self-motivated, hands-on, practical mindset, and capable of setting and reaching ambitious goals
  • Medical, dental, vision, and life insurance available to you starting on your first day of employment
  • Generous time off package including vacation PTO, sick PTO, and 11 company-paid federal holidays.
  • 401(k) with company match and stock options.
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Position: Process Engineer – LPBF Gas Flow

Thank you for submitting your application and for your interest in working with us. We look forward to reviewing your profile and will get back to you shortly if there is a good fit.