Principal Additive Manufacturing Engineer - Sand 3D Printing

Poly6

JOB DESCRIPTION: Principal Additive Manufacturing Engineer – Sand 3D Printing

Cleveland, OH, USA

Join our innovative team where we specialize in the advanced additive manufacturing and automation for industrial casting in aerospace and defense. We partner with Consolidated Precision Products (“CPP”) to pioneer next-generation casting solutions that meet the rigorous demands of quality, durability, and precision required for turbine engines, aerostructures and other defense applications. We are seeking an experienced engineering leader who can lead a new phase of expansion and buildout.

OVERVIEW

The Principal Additive Manufacturing Engineer – Sand 3D Printing will lead Poly6’s initiatives to develop internal capability for producing 3D-printed sand cores for advanced casting processes. This role combines deep expertise in binder jetting processes, strong communication and collaboration skills, and a hands-on approach to technical problem solving. The ideal candidate thrives as a high-impact individual contributor capable of interfacing across engineering, customers, and leadership.

RESPONSIBILITIES

• Lead technical development and establishment of in-house 3D sand printing capability on ExOne and Voxeljet equipment.

• Build and maintain should-cost models for 3D-printed sand cores, factoring in materials, machine operation, and post-processing.

• Work with OEM engineers and product teams to convert casting requirements into detailed specifications for 3D-printed sand core suppliers.

• Partner with stakeholders to simplify sand core designs, reducing part count and assembly labor for downstream foundry processes.

• Conduct technical trials to optimize binder jetting parameters for silica-based sands using phenolic and furan resins.

• Present technical findings to customers and executive audiences with clear, effective communication.

• Document processes, technical learnings, and best practices to ensure knowledge capture and transfer.

• Serve as the technical subject matter expert for both Poly6 and CPP in binder jetting of sand cores.

• Collaborate with manufacturing, quality, and program management teams to integrate 3D sand printing into broader casting workflows.

QUALIFICATIONS

• Bachelor’s or Master’s degree in Mechanical Engineering, Materials Science, Manufacturing Engineering, or similar field.

• Minimum 7+ years of experience in binder jetting additive manufacturing, ideally including ExOne and Voxeljet sand printing applications.

• Proven understanding of sand casting processes and casting design principles.

• Skilled in cost modeling and economic analysis for manufacturing processes.

• Strong interpersonal and presentation skills suitable for engaging technical and non-technical audiences.

• Comfortable working independently in a dynamic manufacturing environment, handling ambiguity and shifting priorities.

• Must be a U.S. person (citizen or permanent resident) due to export control requirements.

PREFERRED EXPERIENCE

• Direct experience with ExOne and Voxeljet binder jetting systems.

• Familiarity with phenolic and furan resin systems for sand printing.

• Experience in defense or aerospace casting programs.

• Understanding of ITAR/EAR regulations and aerospace part qualification standards.

WORK ENVIRONMENT

• Location: On-site in Cleveland, OH

• Travel: Occasional travel (10-15%) for supplier interactions, customer meetings, or technology transfer.

• Schedule: Full-time, Monday to Friday, with flexibility for project demands.

BENEFITS

• Competitive salary range based on experience.

• Quarterly bonus.

• Comprehensive health, dental, and vision insurance.

• 401(k) with company match.

• Paid time off and holidays.

• Professional development opportunities, including CAD certifications and technical training.

• Collaborative and innovative work culture.

HOW TO APPLY

Please submityour resume and a cover letter outlining your experience with sand 3D printing and casting applications with your application.

This position requires access to information protected under U.S. export control laws, including the International Traffic in Arms Regulations and/or the Export Administration Regulations. Please note that any offer for employment may be conditioned on authorization to receive software or technology controlled under these US export laws without sponsorship for an export license. Poly6 is an equal opportunity employer. We do not discriminate based on age, color, genetic information, religion, sex, veteran status, or national origin. Note: This job description is intended to convey information essential to understanding the scope of the position and is not an exhaustive list of skills, efforts, duties, or responsibilities associated with it.

This is a non-management position
This is a full time position