Sr. Metal Additive Process Engineer

Fusion Life Sciences Technologies (www.fusionlifesolutions.com ) is a WBE-certified Healthcare Staffing and Engineering Services provider supporting industries including Pharma, Medical Devices, Aeronautical, Supply Chain, Heavy/Light Industrial, Food & Beverage, and Automotive. We proudly partner with 120+ clients such as Johnson & Johnson, Haemonetics, Delta, Caterpillar, Artisan Chef, Baxter, and many more. Our wide network of consultants and contract-to-hire engineers brings deep expertise across Engineering, Technical, Administrative, Healthcare, Life Sciences, Blue Collar, Skilled Trades, IT, Software Development, Manufacturing, and Supply Chain sectors. What sets us apart is our AI-powered, in-house software's enabling us to source and screen top talent within hours. This ensures rapid response times, high-quality matches, and virtually zero attrition.

Title: Sr. Metal Additive Process Engineer

Location: Irvine, CA

Duration: 6 Months possible extension

Position Summary
Lead the development, optimization, and scale-up of metal additive manufacturing (metal 3D printing) processes through hands-on operation of metal printing equipment, experimental design, and data analytics. Drive process understanding, establish robust manufacturing windows, and qualify parts and components.

Key Responsibilities

• Operate, maintain, and optimize metal additive manufacturing systems.
• Develop and refine print parameters to improve build quality, productivity, and yield.
• Design and execute DOE studies to identify and optimize critical process parameters.
• Troubleshoot printing, powder handling, and post-processing issues using engineering and statistical methods.
• Support equipment and part qualification, process validation, and scale-up into production.

Must-Have Skills

• Hands-on experience with metal additive manufacturing technologies.
• Strong understanding of metal powder behavior, melt pool dynamics, process parameter development, and defect mechanisms.
• Experience designing and executing DOE studies and applying statistical analysis.
• Strong troubleshooting and root-cause investigation skills.

Nice-to-Have Skills

• Machine learning, AI, or predictive modeling for process optimization.
• Design for Additive Manufacturing (DfAM).
• Thermal modeling, FEA, or simulation of metal AM processes.

Preferred Qualifications

• BS/MS in Mechanical Engineering, Materials Science, Manufacturing Engineering, or related discipline.
• 5+ years minimum of experience in metal additive manufacturing process development. (7-10 years' experience would be preferred)

All your information will be kept confidential according to EEO guidelines.