Manufacturing Design Engineer - Powder Materials & Atomization Process

Summary

Imagine what you could do here. At Apple, new ideas have a way of becoming extraordinary products, services, and customer experiences very quickly. Bring passion and dedication to your job and there's no telling what you could accomplish. The people here at Apple don’t just build products — they craft the kind of wonder that’s revolutionized entire industries. It’s the diversity of those people and their ideas that encourages the innovation that runs through everything we do, from amazing technology to industry-leading environmental efforts. Join Apple and help us leave the world better than we found it!

Minimum Qualifications

BS, MS, or PhD in Materials Science and Engineering, Metallurgical Engineering, Mechanical Engineering, or a related discipline. Advanced degree preferred. Hands-on experience in metal atomization, powder metallurgy, materials characterization, and manufacturing process engineering with a strong emphasis on Titanium and Aluminum alloys.

Preferred Qualifications

Deep industry expertise in gas atomization technologies (e.g., Vacuum Induction Gas Atomization [VIGA], Electrode Induction-melting Gas Atomization [EIGA]). Comprehensive knowledge of powder lifecycle & post-processing, including inert classification, sieving, air classification/cyclone separation, blending, degasification, and safe handling/passivation of reactive metal powders. Expertise in powder characterization methodologies and standards (ASTM/ISO) covering: Particle Size Distribution (PSD via laser diffraction, dynamic image analysis). Powder morphology (SEM, circularity, sphericity, satellites, internal porosity via micro-CT/cross-sectioning). Rheology and flowability (Hall/Carney flowmeter, Freeman FT4 powder rheology, tap/apparent density). Interstitial and trace chemistry control ($O, N, H, C, S$ via inert gas fusion / LECO; ICP-OES/MS for alloy constituents). Strong background in circular metallurgy and sustainable feedstocks, including re-atomization of manufacturing scrap/swarf, powder rejuvenation/reuse loops, and minimizing carbon footprint to support Apple’s 2030 carbon neutrality goals. Demonstrated mastery of Design of Experiments (DOE), Statistical Process Control (SPC), Gauge R&R, and data-driven process optimization. Practical understanding of downstream interactions—how powder characteristics (interstitial oxygen pick-up, PSD skewness, flowability) directly influence build density, mechanical properties, and final cosmetic anodization/polishing yields. Robust project management skills with the ability to lead technical initiatives and manage schedules independently across global time zones. Comfort and proficiency working on the production floor at partner atomization plants and test laboratories worldwide.

Description

The Apple Manufacturing Design Materials Process Engineer is accountable for leading the development, qualification, and high-volume deployment of advanced metal powder manufacturing processes across Apple’s worldwide supply base. In this critical, hands-on role, you will specialize in Aluminum (Al) and Titanium (Ti) powder synthesis, gas atomization, powder characterization, and recycling pipelines destined for additive manufacturing process. You will collaborate directly with Apple cross functional teams, as well as our international powder suppliers. You are empowered and expected to bring deep metallurgical creativity, process rigor, and data-driven problem solving to pioneer sustainable, high-yield powder supply chains for Apple products.

Responsibilities

You will own the end-to-end process development, qualification, and scaling of high-performance Aluminum and Titanium alloy powders. You will bridge the gap between upstream raw material sourcing / atomization and downstream component fabrication to guarantee that our powder feedstock delivers unmatched cosmetic, dimensional, and mechanical performance. You will be expected to: Partner with Product Design and Industrial Design to translate mechanical, environmental, and cosmetic goals into strict powder-level raw material specifications. Identify, audit, and validate global atomization partners, melt equipment, and classification systems capable of producing ultra-clean, spherical Al and Ti powders. Establish comprehensive process parameter windows (melt superheat, gas-to-metal ratio, nozzle geometry, atomization gas purity, cooling rates) to control yield curves, particle morphology, and minimize satellites/hollow particles. Define strict inert handling, packaging, storage, and traceability protocols to mitigate moisture pickup, pyrophoric risks, and ambient contamination. Drive DOEs to analyze the impact of raw material inputs (sponge Ti, virgin Al ingot, post-industrial scrap, master alloys) on final powder purity and mechanical/cosmetic consistency. Lead root-cause failure investigations (FA/RCA) on powder defects causing downstream component porosity, inclusion-driven cosmetic streaks, or anodizing inconsistencies. Collaborate with Global Supply Managers to drive technical roadmaps, cost reduction, capacity planning, and yield optimization across the powder supplier matrix. Provide on-site technical leadership during development phases (Proto, EVT, DVT, PVT) and mass production ramp at international supplier facilities. You may be asked to lead development in one or more of the following areas: Scaling EIGA, VIGA, or Plasma Atomization processes for proprietary Titanium and Aluminum formulations. Development of closed-loop Titanium and Aluminum powder recycling and rejuvenation cycles (evaluating multi-generation reuse effects on interstitial pick-up and sphericity). Implementing advanced in-line/real-time quality monitoring systems (acoustic emission, optical pyrometry, automated PSD sensing) for continuous atomization runs. Engineering tailored PSD fractions (e.g., $15–53,\mu\text{m}$ for LPBF, fine cuts for Binder Jetting or MIM) to optimize packing density and surface finish. Standardizing custom chemical clean-room procedures and cross-contamination prevention guidelines between reactive (Ti, Al) and non-reactive metal lines. Correlating melt-source chemistry and atomization dynamics to downstream surface cosmetics (e.g., grain structure, anodizing response, bead-blast texture).