About Our Client
Our client is a leading global provider of high-performance refractory metals and precision-engineered components, serving the aerospace, defence, semiconductor and medical industries. Combining advanced materials science, manufacturing expertise and innovation, they support some of the world’s most demanding applications.

They are now seeking an Additive Manufacturing (AM) Engineer – R&D to help advance next-generation refractory metal additive manufacturing processes. This is a high-impact opportunity to play a key role in developing scientifically validated material processes that will underpin future commercial applications in metal 3D printing.

Position Summary
The AM Engineer – R&D will act as the innovation owner for additive manufacturing within the Research & Development team, responsible for developing and verifying the scientific processes necessary for the future commercial viability of refractory metal alloys. The primary objective of the role is to develop and formally deliver a Qualified Material Process (QMP) compliant with NASA-STD-6030 requirements where applicable.

Key Responsibilities

Material Process Qualification

• Design and execute Design of Experiments (DOEs) on R&D additive manufacturing equipment to evaluate and qualify new refractory metal alloys
• Utilise Statistical Process Control (SPC) to define material allowables
• Develop and finalise the Qualified Material Process (QMP) package

Powder & Post-Processing Collaboration

• Work directly with the in-house powder production team to define powder specifications, evaluate new powder batches and optimise feedstock recycling strategies
• Design and monitor heat treatment and Hot Isostatic Pressing (HIP) trials to achieve required material properties and reduce internal stresses

Technical Documentation & Industry Outreach

• Prepare scientific data for internal technical release and external publications, including papers and patents
• Present technical findings at industry conferences and technical forums
• Represent the business within the advanced manufacturing and materials science community

Equipment & Data Management

• Serve as the primary owner and technical expert for the R&D additive manufacturing printer
• Manage process parameters, build strategies and experimental testing
• Ensure all build files, testing data and documentation comply with CMMC requirements for secure storage of Controlled Unclassified Information (CUI)

Collaboration & Technology Transfer

• Work closely with the AM Technician to run experimental builds and testing campaigns
• Transfer validated Qualified Material Process (QMP) packages to the Production Engineer for industrialisation
• Support verification runs on production printers prior to release of new products

Qualifications

Education

• Bachelor’s degree in Materials Science, Metallurgy or Aerospace Engineering required
• Master’s degree or PhD preferred

Experience

• 3+ years of experience in metal additive manufacturing process development, preferably with high-temperature or refractory alloys
• Proven experience with high-temperature post-processing, including Hot Isostatic Pressing (HIP) and vacuum heat treatment
• 2+ years of experience managing Laser Powder Bed Fusion (L-PBF) production builds
• Experience conducting Design of Experiments (DOE)

Technical Skills

• Proficiency with lab instruments including microscopes, calipers and basic inspection and measurement equipment
• Strong mechanical aptitude and troubleshooting ability
• Experience with powder metallurgy is a plus
• General metrology experience is a plus

Documentation & Communication

• Excellent documentation and organisational skills with strong attention to detail
• Experience presenting technical findings to management and external audiences
• Ability to produce technical research documentation, reports and publications
• Strong verbal and written communication skills in English

Security & Compliance

• Experience managing controlled digital technical data
• Strong commitment to following strict quality, documentation and security protocols

Why Apply

• Opportunity to support advanced materials manufacturing and innovation
• Exposure to aerospace, defence, semiconductor and energy industries
• High-impact laboratory role ensuring material integrity and compliance
• Collaborative culture grounded in technical excellence and operational discipline
• Comprehensive benefits package including health, dental, vision, 401(k) and paid time off

This vacancy is being handled by Kensington360, specialists in Additive Manufacturing recruitment. To find out more or apply in confidence, get in touch today.