Senior Additive Manufacturing Engineer

Role details

Position Overview: The Senior Additive Manufacturing Engineer will own the technical execution, optimization, and continuous improvement of Velo3D’s Rapid Production Solutions (RPS) metal additive manufacturing operations. This role serves as the technical bridge between additive production, post-processing, metrology, and manufacturing engineering—ensuring complex customer hardware progresses from build through shipment with exceptional quality, predictable cycle times, and clear technical ownership.

The ideal candidate is a hands-on manufacturing leader who thrives at the intersection of process development and production execution, driving improvements in yield, throughput, dimensional accuracy, and overall process capability.

Responsibilities - Own post-build technical execution by performing post-print quality evaluations, including visual inspections, process parameter reviews, and initial assessments to ensure parts meet requirements immediately after printing. - Develop, program, and optimize post-processing workflows, including furnace thermal cycles (stress relief, Sol-Age), depowdering processes, and wire EDM operations. - Serve as the technical authority for wire EDM processing of additive builds by developing dynamic cut strategies based on part geometry, surface area, material, and build characteristics.

Design and execute structured experiments to establish process capability and improve repeatability. - Lead Solukon and furnace process development by creating, validating, and maintaining production recipes while partnering with operations to ensure safe, consistent, and efficient thermal processing. - Drive dimensional control and metrology strategies by defining inspection plans, executing 3D scanning workflows, analyzing deviations against CAD and drawings, and generating inspection reports for high-value customer hardware.

- Develop and maintain material- and condition-specific shrink-rate databases to establish scaling factors, compensation strategies, and improved first-build success rates. - Create and implement advanced scaling methodologies, including asymmetric scaling approaches based on build height, geometry, and regional deformation trends. - Provide Design for Additive Manufacturing (DfAM) guidance by analyzing distortion, cracking, support strategies, and process risks to improve part designs and manufacturing outcomes.

- Investigate and resolve additive manufacturing failure modes, including cracking, deformation, and dimensional nonconformance, translating findings into actionable design rules and process improvements. - Partner cross-functionally with EDM technicians, furnace operators, depowdering teams, quality, and shipping/receiving to eliminate process handoff gaps and improve production flow. - Lead structured continuous improvement initiatives focused on throughput, yield, process capability, and manufacturing predictability across EDM, heat treatment, scaling, and inspection processes.

- Support NCR investigations, root cause analyses, and corrective/preventive actions by ensuring lessons learned are incorporated into designs, build files, process standards, and production controls. - Collaborate with manufacturing leadership to prioritize and execute continuous improvement projects aligned with plant objectives. - Support customer-facing technical engagements and demonstrations that highlight Velo3D’s advanced additive manufacturing capabilities when needed.

Qualifications - 8+ years of hands-on experience in metal additive manufacturing, production engineering, or advanced manufacturing environments. - Bachelor’s or Master’s degree in Mechanical Engineering, Manufacturing Engineering, Materials Science, or a related technical discipline. S. Citizenship required due to the nature of company government contract work and associated security requirements. - Strong understanding of GD&T, dimensional inspection methods, scan-based metrology, and translating measurement data into process improvements and compensation strategies.

- Demonstrated experience leading structured continuous improvement initiatives in a production environment, including problem definition, experimentation, data analysis, implementation, and standardization. - Ability to work effectively on the manufacturing floor, collaborate directly with operators and technicians, and resolve technical challenges in real time. - Strong communication and leadership skills with the ability to influence and align stakeholders across engineering, operations, quality, program management, and executive leadership.

About the Company

Velo, Velo3D, Sapphire and Intelligent Fusion are registered trademarks of Velo3D, Inc. Without Compromise, Flow, Flow Developer, and Assure are trademarks of Velo3D, Inc. With the only SupportFree laser powder bed fusion capability, we enable on-demand manufacturing of production quality Titanium, Inconel, and Aluminum parts with an unprecedented degree of design freedom and quality control. The VELO3D award-winning solution includes an integrated offering of hardware and software: Sapphire® metal AM production printer, Flow™ print preparation software, Assure™ quality assurance and control system, and an integrated manufacturing process that runs throughout the printing operation.

Our team enjoys excellent benefits including healthcare coverage and 401(K) employer contributions. We believe in transparency and recognizing exceptional efforts through our monthly all-hands meetings and team member appreciation awards. Our job titles may span more than one career level. The starting base salary for this full-time position is between $115,000 and $130,000. S. The actual base pay is dependent upon many factors, such as work experience, job-related skills, related education, work location, and market demands. The base pay range is subject to change and may be modified in the future.

In addition to a competitive base salary and a comprehensive benefits package, this position may be eligible for other forms of compensation such as participation in a bonus and equity program, as applicable. Velo3D provides equal employment opportunities to all employees and applicants for employment without regard to, and prohibits discrimination and harassment based on, race, color, religion, age, sex, national origin, disability, medical condition, genetic information, military or veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.

This policy applies to all terms and conditions of employment, including recruiting, hiring, placement, promotion, termination, layoff, recall, transfer, leaves of absence, compensation, and training. We may use artificial intelligence (AI) tools to support parts of the hiring process, such as reviewing applications, analyzing resumes, or assessing responses. These tools assist our recruitment team but do not replace human judgment. Final hiring decisions are ultimately made by humans. If you would like more information about how your data is processed, please contact us.