Staff Product Development Engineer - Aerospace & Defense

Role details

Job Purpose As a Staff Product Development Engineer, Aerospace & Defense at VulcanForms, you will own customer products from initial concept through serial production. You will work on a cross-functional engineering team to get the most out of our vertically integrated manufacturing operation, and you will support and continually develop the engineering processes that turn a customer concept into a repeatable, qualified production program with consistent print quality, reliable equipment, and efficient throughput. This is a senior technical individual contributor role.

You will act as the primary technical authority for your products, working across hardware, software, materials, and operations to deliver production-ready parts for our most strategic aerospace and defense customers.

Key Responsibilities

Partner with a cross-functional team of additive, post-processing, and quality engineers to develop part processes that maximize customer value. Evaluate early-stage opportunities for feasibility, working with senior technical staff to define the new product introduction path and with program leads to set clear expectations and keep technical development on track. Work with automation, machining, and finishing process owners as well as outside vendors to apply Design for Manufacturing (DFM) principles from the start of every program.

Support quality engineering in selection and execution of appropriate metrological solutions effectively meet customer needs from a qualification and production perspective. Support production programs by keeping parts moving efficiently through the factory. Support root cause investigations for complex part defects and implement corrective and preventive actions (CAPA) using data analysis and iterative testing. Support the technical execution of First Article Inspections (FAI) and production launches for the A&D vertical. Review and execute change orders in response to customer design changes and internal KPI targets.

Identify improvements to our product development process so that teams work efficiently and consistently meet customer needs. Qualifications 6+ years of progressive, hands-on experience in product or applications development with a preference for candidates with experience in LPBF or similar additive technology. Bachelor's degree in Mechanical, Materials, Aerospace, Biomedical Engineering, or a related field. Expert-level proficiency in advanced 3D CAD software (e.g., Siemens NX, Creo, SolidWorks) Specialized skills with build-preparation tools (e.g., Magics, nTopology, Amphyon) preferred.

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 $124,800 to $171,600. About Us 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.