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Fabri · 19 hours ago

Process Engineer

Framingham, MA

Full-time

Onsite

Mid Level

$125K/yr - $150K/yr

3+ years exp

Fabri is an early-stage investment casting startup building a fully integrated digital foundry. The Process Engineer will lead process development and continuous improvement efforts to enhance the manufacturing steps that determine casting quality, focusing on ceramic building processes and additive pattern production.

ManufacturingPrecious MetalsSoftware

No H1B

U.S. Citizen Only

Responsibilities

Lead root-cause analysis and corrective actions for defects across printing, shelling/drying, thermal processing, and downstream casting outcomes, with a focus on how the introduction of additively manufactured patterns influence the traditional casting process

Design and execute rigorous experimentation programs (DOE), including statistical analysis, measurement system validation, and clear decision criteria

Develop and optimize coating process parameters, slurry chemistry (polymer systems, binder systems, solids loading, rheology), stucco strategy, drying conditions, layer schedules, handling/fixturing

Develop and optimize burnout and thermal processing of printed patterns to improve shell integrity and dimensional stability, including printed infill geometries, polymer chemistry, furnace profiles, ramp/soak schedules, venting strategies, orientation, and fixture design

Own and improve the photopolymer pattern process: printer parameter development, resin handling, resin chemistry, pattern post-processing, print reliability, dimensional stability, throughput, and influence on subsequent process steps

Define key process metrics and implement process controls (SPC where appropriate), including monitoring plans and alarm thresholds

Build characterization and metrology workflows with quality teams to quantify defects and validate improvements (e.g., sectioning, microscopy, dimensional/scan-based methods), and ensure the right data is collected for feedback and reporting

Collaborate with software/automation teams to encode process rules and constraints into production software (e.g., parameter capture, recipe management, traceability, defect tagging, data collection) and to close the loop between process outcomes and automated decision-making

Qualification

Process EngineeringAdditive ManufacturingStatistical AnalysisMaterials ScienceCeramic EngineeringChemical EngineeringMechanical EngineeringAttention to DetailCommunication SkillsCollaborationProblem-Solving

Required

Bachelor's degree in Materials Science/Engineering, Ceramic Engineering, Chemical Engineering, Mechanical Engineering, or a related field

3+ years of experience in hands-on process engineering, process development, or manufacturing engineering (investment casting, additive manufacturing, surface engineering, polymer science, ceramics, thermal processing, or related)

Demonstrated ability to run disciplined DOE programs and apply statistical methods to manufacturing processes

Comfort working on the factory floor and owning outcomes in a fast-paced, multidisciplinary environment

Strong attention to detail and disciplined documentation habits

Strong communication skills and ability to collaborate closely with operations, quality, and software teams

Candidates for this role must be US nationals (i.e., US citizens or lawful permanent residents) to be considered

Preferred

Familiarity with surface engineering, optics, thermo and fluid dynamics, rheology, colloids/suspensions, binders, surfactants, and drying/curing kinetics

Experience with thermal decomposition and processing of polymers and ceramics, and furnace operation, including fixture design and thermal stress mitigation

Experience with optical additive manufacturing processes and post-processing (DLP/SLA or related), especially where thermal processing compatibility matters

Experience with SPC, capability analysis, yield tracking, and structured quality systems

Experience collaborating with software teams to instrument processes and build data-driven feedback loops

Ability to rapidly identify, learn, and reason across diverse, multi-disciplinary physics domains and process steps using a systems-engineering mindset, applying first-principles and strong theoretical fundamentals to solve complex problems efficiently

Experience in a startup with high ownership and ambiguity