LBF Process Design Engineer

LPBF Process Design Engineer Location: Indianapolis, IN Our client is a leading manufacturer of additive machines specializing in metal 3D printing. They are seeking a LPBF Process Design Engineer to join their growing team. As a Process Design Engineer, you will drive the development and optimization of subsystems and process signatures across their LPBF platforms. You will translate thermalfluid dynamics into robust, scalable manufacturing processes, collaborating with machine engineers and quality teams to accelerate product quality and performance. This role blends hands-on experimentation and computer-based modeling and analysis. 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 integrate sensor setups for real-time signature capture and feedback control

CFD & Simulation Modeling

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

• Perform parametric studies and sensitivity analyses to guide process design.

Material Testing Coordination

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

• Coordinate sample preparation, test method selection, and data integration to support process design decisions.

Data Analysis & Visualization

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

• Use statistical tools (DOE, regression analysis) to identify key process drivers and optimize parameters.

Process Optimization & Scale-Up

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

• Support technology transfer activities, guiding scale-up from R&D to pilot and production systems

Cross-Functional Collaboration

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

• Engage with universities and subcontractors to leverage external expertise and resources throughout process design and testing

Documentation & Quality Support

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

• Contribute to internal quality frameworks (PAQ) and support customer audits or DoD submissions

Required Qualifications

• Bachelors or Masters degree in Mechanical Engineering, Materials Science, or related field

• 3+ years of experience in process development, or additive manufacturing

• Experience or familiarity in Python or other coding languages for data visualization and analysis

• Demonstrated ability to design experiments, analyze complex datasets, and distill actionable insights

• Strong time management skills, with ability to coordinate multi-site or cross-disciplinary campaigns

• Excellent written and verbal communication skills for technical and non-technical audiences

Preferred Qualifications

• Direct experience with LPBF systems and metallurgy

• Experience with machineprocess integration, sensor data acquisition, or control system design

• Proficiency with CFD software (ANSYS Fluent, STAR-CCM+, or similar) and data analysis tools (Python, MATLAB)

• Familiarity with design of experiments (DOE) and statistical analysis (Minitab, JMP)

• Knowledge of quality management standards (AS9100, ISO 9001) and regulatory requirements (ITAR, DoD procurement)

If youre interested in learning more about this opportunity, please send your resume to ... .