Senior Process Engineer

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 a Senior Process Engineer, you will play a pivotal role on the core engineering team defining 3D printing processes for our major production programs. Your main objective will be to design, develop, optimize, and implement scalable manufacturing processes for industrial applications utilizing our advanced metal additive manufacturing (AM) systems.

You will define process strategies for customer programs, conduct printing experiments, and analyze outcomes to bridge the gap between initial design and mass production. Collaborating closely with cross-disciplinary experts in machinery, software, controls, and materials, you will continuously improve process capabilities. Your work will directly enable the mass production of high-performance parts that meet or exceed rigorous internal and industrial quality standards.

Additionally, you will be responsible for defining project deliverables, managing execution, documenting progress, and communicating milestones with leadership and program stakeholders. 

• Develop, execute, and analyze process parameters and methodologies to support specific program requirements and scale them for mass production.
• Define and implement process development strategies and roadmaps for advanced metal AM systems, aligning machine capabilities with program goals.
• Apply data-driven approaches to evaluate machine configurations, process data, geometry, and post-print inspections to build a comprehensive database of process capabilities and limitations.
• Partner with hardware, software, controls, and materials teams to provide first-hand feedback on system performance, feature implementation, and operational reliability.
• Stay informed of industry trends and cutting-edge solutions in advanced manufacturing and process engineering to drive continuous optimization.

• 5+ years of industrial experience in Mechanical Engineering, Aerospace Engineering, Materials Science, or a related technical field.
• Strong background in advanced manufacturing, thermal processes, or industrial laser applications (e.g., laser welding, cladding, heat treating, or additive manufacturing).
• 2+ years of hands-on experience in industrial process development, optimization, and scaling.
• Practical understanding of materials/metallogy (steel, aluminum, titanium, or nickel alloys) and familiarity with data analysis tools for process optimization.
• Experience utilizing CAD software (Creo, Autodesk Inventor, SolidWorks) or engineering tools to interface with manufacturing systems.

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 $106,000 to $146,000