Sr. NPI Product Development Engineer

Job Purpose

As a Sr. NPI Product Development Engineer at VulcanForms, you will serve as a principal technical leader responsible for architecting and optimizing our high-speed laser powder bed fusion (LPBF) processes and advanced digital workflows. Your mission is to bridge the gap between complex R&D breakthroughs and full serial production, establishing scalable engineering frameworks that ensure unmatched print quality, system reliability, and manufacturing efficiency across the entire organization.

You will act as a primary technical authority, influencing cross-functional roadmaps across hardware, software, materials, and operations to deliver high-consequence, production-ready parts for our most strategic global customers.

Key Responsibilities

• Architect, govern, and scale integrated LPBF process workflows from initial R&D through high-volume serial production, systematically elevating Manufacturing Readiness Levels (MRL) across the organization.
• Lead the development, standardization, and optimization of core LPBF process recipes and complex build configurations; define the platform standards that ensure repeatability and traceability across the VulcanForms fleet.
• Synthesize highly complex customer and market requirements into foundational engineering specifications; champion top-down Design for Additive Manufacturing (DfAM) methodologies that maximize geometric freedom while balancing supports, tolerances, and metallurgical performance.
• Oversee the technical execution of First Article Inspections (FAI) and critical production launches for high-stakes industries, including aerospace, defense, medical, and semiconductor.
• Serve as the definitive technical subject matter expert (SME) for tier-one customers, program management, and executive leaders—driving alignment on production roadmaps, steering technical reviews, and resolving high-priority engineering challenges.
• Own systemic root cause investigations for complex print defects, implementing org-wide corrective and preventive actions (CAPA) through advanced data analytics and iterative testing.
• Drive cross-functional collaboration with downstream automation, machining, and finishing process owners to embed comprehensive Design for Manufacturing (DFM) principles from day one.
• Mentor and coach junior and mid-level engineers, fostering a culture of technical excellence; establish standard operating procedures (SOPs), quality control standards, and change management logs to ensure strict production compliance.

Qualifications

• 3+ years of progressive, hands-on experience in product or applications development, with a documented track record of scaling LPBF or directed energy deposition (DED) processes into high-volume manufacturing environments.
• Bachelor's degree in Mechanical, Materials, Aerospace, Biomedical Engineering, or a related field; Master’s or Ph.D. is highly preferred.
• Expert-level proficiency in advanced 3D CAD software (e.g., Siemens NX, Creo, SolidWorks) along with specialized build-preparation tools (e.g., Magics, nTopology, Amphyon).
• Deep mastery of GD&T, advanced statistical process capability, tolerance stack-up analysis, and complex DFM/DfAM constraints.
• Outstanding leadership and communication skills, with a proven ability to influence technical roadmaps, align multidisciplinary stakeholders, and mentor engineering talent.
• Strong working knowledge of subtractive manufacturing operations (5-axis milling, turning, EDM) and their integration with additive workflows.

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 $171,000.