Additive Mfg & Testing Engineer

Who is Senior plc?

Senior plc is an international, market-leading, engineering solutions provider with 30 operating businesses in 13 countries. Senior designs, manufactures and markets high-technology components and systems for the principal original equipment producers in the worldwide aerospace, defense, and land vehicle and power & energy markets. The Group is split into two divisions, Aerospace and Flexonics, servicing five key sectors.

Our global values underpin what we do, and how we do it ...

Safety - Integrity - Customer Focus - Respect & Trust - Accountability - Excellence

Who is SSP?

Senior Aerospace SSP, specializes in designing, manufacturing, and qualifying complex ducting systems for aerospace applications. Since its humble roots in 1945, the campus has now expanded to include a 59,000 sq. ft high-volume production facility, in addition to its legacy 131,000 ft2 main buildings which combined, accommodate over 500 employees. Vertically integrated with its own foundry, fabrication shop, and ISO certified engineering lab, Senior Aerospace SSP acquired by Senior PLC in 1995 and has continued its expansion into new programs and technologies.

Why join SSP?

Senior Aerospace SSP is the leader of innovative design and manufacturing methods in the area of complex aerospace systems. Joining out team will provide you with a rewarding career with a tight-knit and collaborative team. You will also enjoy a competitive compensation package that includes a market-led base salary, comprehensive benefits package along with wellness benefits, matching 401K plan and paid time off. Apply today for an opportunity to join our team!

If offer of employment is made it will be contingent upon passing all of the following: Drug Test, Background Check, ITAR and U.S. Export Compliance Screening.

What does the job involve?

Summary:

The Additive Manufacturing (AM) & Testing Engineer will be responsible for both the optimization and oversight of the AM processes, in addition to the Test Engineering responsibilities.

Essential Duties and Responsibilities:

Under general supervision, must be able to perform a variety of job duties including, but not limited to:

Additive Manufacturing (AM) Responsibilities: The person in this role will be responsible for optimizing and overseeing AM processes, including pre- and post-print processing, to ensure the efficient and accurate production of components, whether in R&D or production phases. This engineer is responsible for material selection, machine operation, and maintenance, and ensuring that designs are optimized for the AM process. Duties are as follows:

• Process Development and Optimization:
  • Responsible for maintaining and optimizing all AM processes to ensure efficiency, accuracy, and cost-effectiveness.
  • Work on improving existing processes and develop new methods to enhance productivity and product quality.
  • Follow work orders, procedures, specifications, and test instructions, and coordinate with our staff at different post processing steps including x-ray, pen inspection, heat treatment, polishing, etc.
• Material Selection and Testing:
  • Evaluate and select appropriate materials for AM based on project requirements and specifications.
  • Conduct various material testing to analyze the properties of powder and printed coupons in our Materials and Engineering Test Labs and present test results to the team.
• Machine Operation and Maintenance:
  • Monitor and record operational information such as functional issues, material consumption rates, and build completion dates.
  • Operate and maintain metal AM machines, ensuring they function correctly and produce high-quality components.
  • Troubleshoot technical issues related to our AM equipment and schedule service when needed.
  • Troubleshoot mechanical, optical laser, electrical, and build issues for the AM machines.
• Design for Additive Manufacturing (DFAM):
  • Collaborate with design teams to optimize product designs for AM, considering factors such as geometric complexity and part orientation for optimal results.
• Prototyping and Production:
  • Produce prototypes and functional components using our metal AM machines, meeting project timelines and adhering to quality standards.
  • Scale up additive manufacturing processes for large-scale production while maintaining quality and efficiency.
• Documentation and Reporting:
  • Maintain detailed records of additive manufacturing processes, parameters, materials, and testing results.
  • Generate comprehensive reports to document the outcomes of additive manufacturing projects, highlighting successes, challenges, and potential improvements.

Test Lab Responsibilities: Additionally, the person in this role will be responsible for the following:

• Test Plan Development:
  • Design LabVIEW data acquisition and closed loop control algorithms for automated tests.
  • Develop test equipment software and hardware requirements to ensure successful completion of tests.
  • Develop and document R&D charter engineering test plans and procedures.
  • Work with Design Engineering to review and evaluate test requirements and procedures to ensure completeness and feasibility of test programs

• Documentation and Compliance:
  • Document test procedures, results, and any deviations from expected outcomes. Ensure compliance with relevant testing standards and industry best practices.

• AM Testing and Maintenance:
  • Maintain all Engineering Lab test equipment related to Additive Manufacturing, as well as their requirements and capabilities.
  • Responsible for the compilation, organization, and communication of test data to the Project Engineers.
  • Work with Project Engineers to develop test equipment drawings, procedures, and requirement compliance matrices.
  • Support performance implementation and process improvements in the Engineering Lab

• ISO17025:
  • Apply knowledge and/or experience with ISO 17025 Quality Management System requirements for qualification test labs.

In addition to the above, AM & Testing Engineers are to maintain an organized, clean, and safe work area using safety standards and expectations while adhering to all quality practices. Senior is an Equal Opportunity Employer. Reasonable accommodation may be made to enable individuals with disabilities to perform essential functions.

Education and/or Experience:

• Must have a bachelors degree in Mechanical Engineering, Industrial Engineering, Materials Science, and/or chemistry, or a related field of study. Specialized coursework or concentration in Additive Manufacturing (3D Printing) and/or Testing methodologies is highly beneficial. This may include courses in additive manufacturing processes, materials science, CAD/CAM, quality assurance, and testing techniques.
• Prior experience in additive manufacturing, either through internships, co-op programs, or entry-level positions, is valuable. Familiarity with 3D printing technologies, materials, and machine operation is essential.
• Experience with testing equipment and creating test modules, executing AM tests, powder testing, SEM, and running failure analysis would be highly beneficial.
• Involvement in engineering projects during academic studies or in a professional capacity that required collaboration with cross-functional teams and hands-on experience with AM process and AM testing.
• Strong interpersonal skills and experience collaborating with multidisciplinary teams to ensure effective communication and successful project outcomes.
• Demonstrated problem-solving abilities in identifying and resolving issues related to additive manufacturing, testing, and product quality.
• An inclination towards continuous learning and staying updated with advancements in additive manufacturing technologies, testing methodologies, and industry best practices.
• Analytical Thinking: Ability to analyze data, identify trends, and make data-driven decisions to improve processes and product quality.
• Strong team collaboration and communication skills to work effectively within a team environment and across various departments.
• A keen eye for detail to ensure accuracy and precision in additive manufacturing and testing processes.
• Familiar with ISO 17025 Quality Management System requirements for qualification test labs.

Required Skills:

• Language: Ability to read, analyze, and interpret general business periodicals, professional journals, technical procedures, or governmental regulations. Ability to write reports, business correspondence, and procedure manuals. Ability to effectively present information and respond to questions from groups of managers, clients, customers, and the general public. Ability to establish cooperative relationships of all levels.
• Reasoning Ability: Ability to apply common sense understanding to carry out detailed, written and oral instructions. Ability to solve problems involving many variables in various situations. Ability to analyze, interpret and modify complex technical and organization problems and consolidate essential facts and figures objectively.
• Mathematical Skills: Ability to calculate figures and amounts such as discounts, interest, commissions, proportions, percentages, area, etc. Ability to use shop mathematics.

• Other Abilities: Must have knowledge of MAPICS manufacturing software; MS Excel spreadsheet software, MS Word, and Word Processing software. Must be able to lead a cross functional team of supervisors in a fast-paced, changing environment. Must be able to withstand subjective pressure in defense of final decisions.

ITAR Compliance:
* Access to our facility (and, therefore, employment) is restricted under the International Traffic in Arms Regulations (ITAR) and/ or Export Administration Regulations (EAR) to U.S. Citizens, lawful permanent residents, U.S. refugees, asylees or temporary residents under amnesty provisions [as defined in 8 USC 1324b(a)(3)] and properly licensed foreign persons. Applicants receiving a conditional offer of employment will be required to provide information to determine whether they are subject to these regulations and, if so, to assess their country of chargeability for export control purposes. Additionally, potential employee's names will be screened against the Consolidated Screening List (maintained by the United States government) to determine eligibility to receive technical data.