Founded in 2015 to develop the world’s first industrially scalable laser metal additive manufacturing solution, VulcanForms is reshaping how the world manufactures critical products. We build and operate advanced digital infrastructure that enables innovation, accelerates growth, and supports sustainability across aerospace, defense, medical, and other essential industries. Through our vertically integrated capabilities, including scalable additive manufacturing and precision machining, we deliver true end-to-end production at scale by combining cutting-edge technology with a foundation of proven industrial craftsmanship. Our team brings deep expertise in manufacturing, materials science, software, automation, and operations, united by a shared commitment to quality, curiosity, and accountability. We foster an inclusive culture where people take ownership, solve meaningful problems, and continuously learn, because we believe diverse perspectives lead to better outcomes.
As an NPI Quality Engineer, you will serve as the front-line investigator for non-conformances, material defects, and process variances across metal additive manufacturing and post-processing operations. Reporting to Quality Leadership, your core mission is to dissect failed builds, perform physical and metallurgical teardowns, collect statistical evidence, and drive initial root-cause containment so engineering teams can implement permanent fixes.
Key Responsibilities- Perform detailed physical, optical, and mechanical failure analysis on non-conforming metal additive builds, machined features, and sub-assemblies.
- Respond immediately to line stoppages and non-conformances (NCs); lead immediate quarantine/containment actions and document non-conformance records with detailed photo, dimensional, and fractographic evidence.
- Work closely with the metallurgical and metrology labs to coordinate tensile testing, density checks, sectioning, polish/etch microstructural reviews, and CMM/optical scans for failed parts.
- Partner with Senior Quality Engineers and Metallurgists to execute structured 8D root-cause investigations—analyzing laser parameters, powder lot history, thermal profiles, and tool paths.
- Serve as a key technical contributor on the Material Review Board (MRB); track defect trends, maintain non-conformance Pareto logs, and present monthly failure-mode data to engineering teams.
- Review Device History Records (DHR), machine logs, and raw material certificates for failed lots to isolate batch-level or machine-level systemic variables.
- 2+ years of quality engineering, failure analysis, or metallurgical lab testing experience in precision hardware or advanced manufacturing.
- Bachelor’s degree in Materials Science, Metallurgy, Mechanical Engineering, or Quality Engineering; equivalent hands-on experience will also be considered.
- Hands-on experience with basic failure analysis tools (optical microscopy, fractography, hardness testing, sectioning/polishing), basic GD&T, and 8D/5-Why root-cause methodologies.
- Direct experience identifying metal additive manufacturing defect modes (e.g., keyholing, lack-of-fusion porosity, delamination, residual stress cracking) or hands-on involvement with destructive mechanical testing of titanium/nickel alloys.
- Proficiency in tracking non-conformance data, leveraging ERP/PLM systems for end-to-end lot traceability, and performing statistical Pareto or yield trend analysis.
VulcanForms offers a competitive salary and equity package. Actual compensation is based on factors such as the candidate's skills, qualifications, and experience. In addition, VulcanForms provides comprehensive benefits including medical, dental, vision, and life insurance; generous paid time off; and a 401(k) plan with company match.
The annual base salary range for this position is $75,000 to $103,000.
Skills Required
- 2+ years of quality engineering, failure analysis, or metallurgical laboratory testing experience in precision hardware or advanced manufacturing
- Bachelor’s degree in Materials Science, Metallurgy, Mechanical Engineering, or Quality Engineering, or equivalent hands-on experience
- Hands-on experience with optical microscopy, fractography, hardness testing, sectioning and polishing
- Basic GD&T knowledge
- Experience with 8D and 5-Why root-cause methodologies
- Experience identifying metal additive manufacturing defect modes
- Hands-on destructive mechanical testing experience with titanium or nickel alloys
- Proficiency tracking non-conformance data and using ERP or PLM systems for lot traceability
- Experience performing statistical Pareto or yield trend analysis
What We Do
VulcanForms builds and operates advanced digital manufacturing infrastructure that enables the world's critical industries to innovate, grow, and deliver sustainable impact. A MIT-born company, VulcanForms has invented and commercialized the world’s first industrially scalable metal additive manufacturing (AM) solution and pioneered integrated digital production systems. Combining breakthrough technologies in additive and subtractive manufacturing, industrial automation, digital thread and engineering expertise, the company serves leading medical, defense, aerospace, and semiconductor companies, producing precision components and assemblies. For more information, visit www.vulcanforms.com.
