R&D Engineer AM

Job Title: R&D Engineer II – Powder Development

Location: Pennsylvania, USA

Salary: $120k – $130k

A company specializing in manufacturing metal powders and metal products is hiring an R&D Engineer to join the team in Pennsylvania.

The R&D Engineer is responsible for identifying and leading process developments, and product improvements, and facilitating the transition of lab-scale processes to full-scale production.

Essential Functions:

• Develop and implement programs to advance refractory powder products for additive manufacturing that adhere to established manufacturing practices, quality standards, and safety protocols.
• Identify necessary capital investments to support development initiatives and achieve R&D objectives.
• Lead the design, execution, and analysis of experiments to produce high-performance powders.
• Support the production of specialized additive powders for sectors such as medical, defense, and energy.
• Work hands-on with equipment, supporting other engineers and research associates in maintenance, repairs, and process improvements.
• Oversee customer powder evaluations across various additive manufacturing platforms.
• Engage actively with powder customers, end users, and industry organizations through conferences, exhibitions, presentations, and meetings.
• Participate fully in the company’s safety culture by sharing safety topics, completing safety training, and engaging with other departments.

Qualifications:

• BS in Materials Science, Metallurgy, Chemical, or Mechanical Engineering
• 5 to 15 years of experience in metal processing, particularly in metal powders
• Proven technical leadership and project management skills
• Experience working in both laboratory and production environments
• Ability to mentor and guide junior personnel
• Proficiency in data management and record keeping
• Familiarity with MS Office and statistical software (e.g., JMP, Minitab)
• Solid understanding of statistics, including data analysis and design of experiments (DOE)
• Experience with analytical techniques such as SEM, particle size analysis, and mechanical testing
• Ability to travel domestically and internationally up to 10%
• Practical experience with additive manufacturing technologies (e.g., laser powder bed fusion, directed energy deposition, selective laser melting, electron beam additive, binder jet, metal injection molding, cold spray, thermal spray)

Preferred Qualifications:

• Advanced degree (MS or PhD) in Materials Science, Metallurgy, Chemical, or Mechanical Engineering
• Background in refractory metals production and applications
• Experience in root cause and failure analyses (RCCA, 5 Whys, PFMEA)
• Familiarity with structured product development processes
• In-depth understanding of metal powder processing techniques (e.g., milling, crushing, screening, hydride/dihydride) and metal powder handling safety

Click apply or speak to Liam Atkinson for the full details at latkinson@kensingtonadditive.com