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General Atomics Aeronautical Systems · 4 hours ago

Additive Manufacturing Engineer, Fused Deposition Modeling

Poway, CA

Full-time

Onsite

Mid, Senior Level

$81K/yr - $142K/yr

4+ years exp

General Atomics Aeronautical Systems, Inc. (GA-ASI) is a leader in remotely piloted aircraft and advanced surveillance systems. They are seeking a Plastics/Polymer Additive Manufacturing Engineer to support the Fused Deposition Modeling (FDM/FFF) production operation team, focusing on design, process qualification, and continuous improvement in manufacturing operations.

EnergyEnergy EfficiencyManufacturingWireless

No H1B

Security Clearance Required

U.S. Citizen Only

Responsibilities

Subject Matter Expert (SME) on industrial FDM/FFF AM and key interface with key engineering stakeholders such as design, materials, process and quality

DfAM FDM/FFF SME and main point contact for internal stakeholders, to support design engineering’s learning and teaching of DfAM specific to FDM/FFF AM, as well as supporting software tool assessment and testing to support manufacturing and engineering AM efforts

Support with plastics/polymer AM suppliers/contract manufacturers qualification, relationships and visits

Responsible for industrial production-focused AM process development, qualification, implementation, and continuous improvement to enhance Quality / Yield, reduce Cost, and improve Productivity / Schedule

Initiate and lead lean manufacturing process improvement projects

Support and lead the planning and implementation of AM (incl. post-processing) equipment and associated processes and safety

Identify and assist in addressing safety issues on the manufacturing floor

Support manufacturing production planning and coordination, execution and operations process development

Provide production support to AM operation team (technicians and production lead)

Document manufacturing processes and assembly work instructions in conjunction with T&O Planning

Assist and drive AM quality and inspection process improvement related to plastics AM

Support with internal needs for AM CAD designs to assist with AM group operations

Disposition non-conforming parts, identify root cause analysis, and implement corrective and/or preventive action to reduce scrap and rework

FDM/FFF AM-related project plan development and management

Participation in internal and external AM group representation (e.g. conferences, collaboration groups, executive management reviews, etc.)

Collaborate with Design Engineering during design release, application development, prototyping and first article manufacturing of FDM/FFF components

Support and lead technology and material exploration, assessment and incubation

Qualification

Fused Deposition ModelingDesign for Additive ManufacturingCAD software proficiencyAviation/Aerospace experiencePost-processing equipment knowledgeMicrosoft Office SuiteSAP systemsNetworking abilityTeam collaborationCommunication skillsSelf-driven

Required

Typically requires a bachelors degree, masters degree or PhD in engineering or a related technical discipline from an accredited institution and progressive engineering experience as follows; four or more years of experience with a bachelors degree or two or more years of experience with a masters degree. May substitute equivalent engineering experience in lieu of education

Extensive experience with Fused Deposition Modeling (FDM/FFF) AM technologies in a production industrial environment. Direct experience with Stratasys production printers and their associated file preparation software is highly desired

Experience in Aviation/Aerospace/Unmanned Aerial Systems industry is desired, but not necessary

Experience with AM applications specific to Aviation/Aerospace/Unmanned Aerial Systems is desired, but not necessary

Experience with the entire FDM/FFF AM part production workflow from business considerations, design release and review, pre-print considerations and planning (incl. support strategy, file preparations, etc.), printing, post-processing, qualification, and inspection process

Direct experience with FDM/FFF-associated post-processing equipment and safety best practices and PPE

Working knowledge of other adjacent FDM/FFF and/or polymer AM technologies, and their associated characteristics and applicability/use cases

Expertise in Design for Additive Manufacturing (DfAM), specifically related to FDM/FFF AM. Ability to demonstrate/provide examples of designs achieved. This assumes proficiency with at least one major CAD platform (e.g. Siemens Nx, PTC CREO, CATIA, ProE, etc.)

Experience with major FDM/FFF-related AM suppliers (service bureaus, contract manufacturers, materials and hardware providers, software providers, etc.)

Background knowledge of conventional manufacturing processes (complementary to FDM/FFF AM, such as CNC machining, bonding, coating, plating, infiltrating, painting, injection molding, etc.) is a plus

Clearly and effectively communicate both verbally and in written form to both technical and non-technical audiences, especially regarding manufacturing processes, engineering issues and proposed changes, and quality issues and dispositions

Ability to form and foster rich AM networking and keep engaged

Experience with Microsoft Office PowerPoint, Project, Excel and Visio

Experience with SAP systems is an advantage

Must be able to work both independently and in a team environment

Must be self-driven, like to innovate, and want to learn more and more

Must be able to obtain and maintain a DoD Security Clearance

Ability to influence others, develop a plan and rally a team around it, lead small team

Able to work extended hours and travel occasionally as required