The Process Development Engineer is responsible for leading internal R&D (IRAD) and customer-funded projects to develop, optimize, and validate MELD manufacturing processes. This role drives process innovation from concept through qualification by designing and executing process development activities, analyzing results, and establishing robust process specifications. The engineer collaborates closely with Materials & Processes, Quality, Engineering, and Manufacturing teams to transition developed processes into production, providing the technical data and documentation required for implementation by Quality and Production team. The position also supports proposal and state of work development, project management, technical documentation, and continuous improvement initiatives while advancing MELD's manufacturing capabilities.
Lead MELD process development, optimization, and validation of manufacturing new materials, material combinations, repair applications, and novel manufacturing solutions.
Key Responsibilities
Process Development & Optimization
- Lead prototyping, process parameters tuning, and thermo-mechanical processing (TMP) studies for steels, copper, magnesium, aluminum, titanium, nickel, and other alloys.
- Develop, evaluate, and optimize processing parameters to deposit complex components, achieve target material performance, and optimize manufacturing efficiency.
- Analyze experimental data and communicate technical findings and recommendations to internal stakeholders.
- Design, execute, and lead experimental process development programs using metallurgical principles, statistical methods, and empirical engineering approaches.
Technical Expertise & Lab Support
- Serve as a technical expert in MELD process technology through hands-on operation, programming, troubleshooting, and continuous improvement of MELD equipment, tooling, machine hardware, and software.
- Support materials characterization and metallurgical laboratory activities, including heat treatment optimization, sample prep, mechanical testing, microstructural characterization, and failure analysis as required.
- Monitor advancements in metallurgy, materials science, solid-state joining/manufacturing, and additive manufacturing technologies to identify opportunities to incorporate emerging innovations.
Operations & Project Management
- Support manufacturing operations by investigating process-related issues, identifying root causes, and implementing robust process improvements.
- Lead project management activities including planning, execution, timeline tracking, and budget management of assigned projects.
- Promote robust engineering practices, process standardization, continuous improvement, and a strong safety culture, including participation in 6S Lean initiatives.
- Contribute to the protection of MELD intellectual property through invention disclosures, patents, and trade secrets. [1]
Collaboration & Documentation
- Collaborate with internal and external stakeholders (M&P, Quality, Engineering, Manufacturing, Sales, and Production teams) to develop new applications, qualify processes, and execute projects on schedule.
- Support business development through proposal preparation, technical volume writing, Statement of Work (SOW) development, and project planning.
- Prepare technical documentation including test plans, process specifications, standard operating procedures, technical reports, and customer deliverables.
- Present project status, technical results, and recommendations clearly to management and customers.
Position Requirements
- Education: Minimum Bachelor’s degree in Materials Science & Engineering, Metallurgy, Mechanical Engineering, Manufacturing Engineering, or related fields.
- Experience: Minimum 2 years of industry experience in additive manufacturing, metallurgy, processing, or manufacturing (+4 years preferred).
- R&D Skills: Experienced with R&D processes accompanied by strong problem-solving skills.
- Execution: Detail-oriented with the ability to document details, follow established processes, and manage multiple priorities independently or within a team.
- Communication: Effective verbal and written communication skills with a proven ability to develop technical documentation
Job Type: Full-time
Benefits:
- 401(k)
- 401(k) matching
- Dental insurance
- Health insurance
- Health savings account
- Life insurance
- Paid time off
- Retirement plan
- Vision insurance
Education:
Experience:
- process engineering: 1 year (Preferred)
Work Location: In person
