LPBF Process Design Engineer

As a Process Design Engineer, you will drive the development and optimization of subsystems and process signatures across our LPBF platforms. You will translate thermal–fluid dynamics into robust, scalable manufacturing processes, collaborating across the organization to accelerate product quality and performance. This role blends hands-on experimentation and computer-based modeling and analysis. You will also be responsible for designing and setting up build files using Materialise software and performing machine calibration activities to ensure optimal system performance and process consistency.

Key Responsibilities

• Process Characterization & Signatures

Design and execute experiments to map thermal, optical, and fluidic signatures of LPBF subsystems (e.g., powder delivery, melt pool dynamics, gas flow, scanner timing, laser intensity profiles)

Develop and validate CFD models for melt-pool dynamics in Flow3D.

Design, configure, and optimize build files using Materialise software, incorporating support strategies, part orientation, and parameter settings.

Perform and Document LPBF machine calibration procedures (e.g. laser focus, scanner alignment, gas flow tuning).

Plan and manage experimental campaigns with commercial testing laboratories and university research labs for powder characterization, CT scanning, microstructure evaluation, and mechanical testing.

Build data pipelines and dashboards in Python (or similar) for visualization of process variables, test results, and simulation outputs.

Apply root-cause analysis and DOE methodologies to improve part quality, yield, and reproducibility

Work closely with R&D, machine design, and quality systems to embed process insights into product requirements

Draft process design reports, technical presentations, and quality protocols (e.g., AS9100, ASTM standards)

Required Qualifications

Preferred Qualifications

What We Offer :

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