Additive Manufacturing Engineer

4 days ago

Columbia, South Carolina, United States Kaiser Aluminium Full time
Job Title: Additive Manufacturing Engineer

We are seeking a highly skilled Additive Manufacturing Engineer to join our team at Kaiser Aluminum Imperial. As an Additive Manufacturing Engineer, you will be responsible for developing and executing manufacturing process plans for metal additive manufacturing, using primarily, but not limited to, Laser Powder Bed Fusion.

Key Responsibilities:
  • Execute and oversee raw materials characterization, conformance to specifications and retention of associated data
  • Provide supporting information to sales and estimating staff for additive components RFQs
  • Contribute AM and component test vantage inputs to job kickoff requirements reviews
  • Prepare customer part models for 3D metal printing in CAD environment (material additions for post-machining, tie-down ribs, other required modifications)
  • Prepare build project files for 3D metal printing, including parts and test coupons layout, support and identification
  • Prepare machine build file utilizing approved release build parameter files for specific metal alloys and layer thicknesses
  • Manage AM job scheduling and execution, including raw materials supply and recycled metal powder management
  • Oversee AM operators' performance of job duties, including LPBF unit build preparation, execution, removal, depowdering and build plate removal, along with associated process signoffs and data retention
  • Work with AM operators and facilities staff on metal AM unit planned and unplanned maintenance activities and record keeping
  • Perform, oversee and retain data for component pressure, leak, flow, particle count testing and cleaning requirements
  • Perform, oversee and retain data for 3D printed metal coupon chemical composition and mechanical property testing requirements
  • Manage jobs through the AM workflow such that quality management system and digital thread requirements are consistently met
  • Perform and oversee the revision of existing QMS documents and generation of new documents as required
  • Gain familiarity and knowledge of industry specifications (ASTM, AMS, ISO, etc.) referenced on customer drawings and/or manufacturing specifications and advise operations of implications to manufacturing workflow and processes
  • Support sales/business development via review of customer requests, participation in virtual or in-person customer meetings, and attendance of relevant industry trade events, requiring occasional travel
Requirements:
  • Energetic, positive, self-starter with the ability to work autonomously while simultaneously leading and developing a high performing team
  • B.S. or advanced degree in related engineering or technical field
  • A minimum of two (2) years of experience in an engineering position supporting Additive Manufacturing
  • Understanding of metal laser powder bed fusion platforms
  • Experience redesigning components for metal laser powder bed fusion
  • Knowledge and experience with metal AM post-processing (subtractive manufacturing and heat treatment)
  • Experience with engineering analysis tools and CAD and AM data preparations software (e.g. Inventor, Magics, GibbsCAM, etc.)
  • Experience with data processing and analysis
  • Disciplined and systematic, with strong organizational and time management skills
  • Experience with Quality Management Systems with associated certifications
  • Ability to effectively collaborate with stakeholders across internal departments and others external to the organization

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