The role of R&D Engineer II includes identifying and leading process development, process and product improvements, and the transition of lab-scale processes to production. The Powder Development Engineer supports production of additive powders via spheroidization, chemical processes, and outside vendor coordination. The Engineer interacts with customers, vendors, and additive manufacturing industry organizations in order to increase technical knowledge, gain information on market requirements, and to promote company products and capabilities. The Engineer provides leadership and guidance to junior engineers and research associates, and promotes GAM's safety message through daily work and interaction with others.
Essential Functions:
Create and plan programs for the development of refractory powder products for additive manufacturing which align with GAM's manufacturing practices, quality standards, and safety culture.
Identify capital investments needed to support development programs and achieve R&D goals.
Lead the design, execution, and analysis of experiments for the development of industry-leading powders.
Contribute to the production of high-value additive powders for use in industries such as medical, defense, and energy.
Work hands-on with equipment assisting other engineers and research associates with maintenance, repairs, and equipment improvements.
Support customer powder evaluations across additive manufacturing print platforms.
Engage with powder customers, end users, and materials/additive manufacturing organizations through conferences, exhibitions, presentations, and meetings.
Participate fully in GAM's safety culture including sharing safety topics, staying current on safety training, and engaging with other departments.
Minimum Requirements and Competencies:
BS in Materials Science or Metallurgy; Chemical or Mechanical Engineering
5 to 15 years' experience with metal processing, preferably metal powders
Demonstrated technical leadership in project management
Experience with both laboratory and production environments
Strong written and verbal communications
Competency in teaching and influencing junior personnel
Excellence in data management and record keeping
Proficiency with MS Office and statistical software (ex. JMP, Minitab)
Hands-on work ethic with strong mechanical aptitude
Understanding of statistics including data analysis and design of experiments (DOE)
Experience with analytical techniques such as SEM, particle size analysis, mechanical testing
Able to travel up to 10% domestic and international
U.S. citizen or permanent resident status
Preferred Qualifications:
Advanced degree (MS or PhD) in Materials, Metallurgy, Chemical or Mechanical Engineering
Hands-on experience with additive manufacturing technologies such as laser powder bed fusion, directed energy deposition, selective laser melting, electron beam additive, binder jet, metal injection molding, cold spray, thermal spray
Background with refractory metals production and/or application
Experience in root cause and failure analyses (RCCA, 5 Whys, PFMEA)
Familiarity with gated product development processes
Deep understanding of metal powder processing technologies (milling, crushing, screening, hydride/dehydride) and metal powder handling safety