Additive Manufacturing Materials Engineer – Parameter Development in Concord

GM Performance Power Units is seeking an Additive Manufacturing Engineer to lead the development, validation, and continuous improvement of laser powder bed fusion (LPBF) processing parameters. This role is focused on parameter science, data-driven optimization, and process robustness, ensuring additive manufacturing builds are fast, repeatable, and capable of delivering championship-caliber performance. The engineer will own parameter windows end-to-end—from experimental development through IQ/OQ/PQ qualification—and partner closely with Design, Operations, Automation, and Quality teams to deploy stable, production-ready AM processes.

Responsibilities

• Develop, optimize, and maintain LPBF process parameter sets using structured DOE methodologies (including full factorial, fractional factorial, and Taguchi robust design principles) to balance cost and throughput while maintaining robust parameter windows.
• Develop advanced scan strategies to improve part quality, feature fidelity, and product performance.
• Own and lead IQ / OQ / PQ for LPBF machines, parameter sets, and process changes, using DOE backed evidence to demonstrate capability and repeatability.
• Apply SPC and data analytics to DOE results, production builds, and in-situ monitoring data to detect drift, quantify process capability, and drive continuous improvement.
• Partner with the AM & Materials team to characterize material behavior, correlate process conditions to mechanical performance, and generate AM design allowable for qualified processes.
• Develop, industrialize, and maintain in-process monitoring and post-build reporting tools (MES, sensor data, in-situ monitoring, inspection analytics) to support production-level quality assurance and traceability.

KPIs

• Robust LPBF parameter sets released using DOE-based methods.
• Demonstrated quality and performance improvements from advanced scan strategies.
• On-time completion of IQ / OQ / PQ for machines and process changes.
• Stable SPC performance and rapid detection of process drift.
• Production adoption of in-process monitoring and post-build reporting tools.
• Reduction in defects, rework, or escapes attributable to process optimization.

Requirements

• Bachelor’s or Master’s degree in Materials Science, Mechanical, or Manufacturing Engineering.
• 2+ years of experience in metal additive manufacturing (LPBF preferred).
• Strong knowledge of powder metallurgy, heat treatment, and AM process development.
• Proficiency in DOE, SPC, and data analytics tools (Minitab, JMP, or Python).
• Familiarity with AS9100 / Nadcap, PFMEA, and QMS documentation.
• Skilled in AM software such as 3DXpert, Dyndrite, or Materialise Magics.

Why Join Us

You’ll play a pivotal role in ensuring the reliability and performance of a next-generation Formula 1 power unit. Our culture rewards precision, innovation, and the relentless pursuit of performance.

Please note: GM Performance Power Units and all affiliated companies are Equal Opportunity employer(s). Minorities, women, veterans, and individuals with disabilities are encouraged to apply.