Process Engineer

General Description:  

Seurat Technologies is seeking a highly motivated Process Engineer - Materials Development to join the process engineering team to work on a revolutionary and proprietary laser powder bed fusion (LPBF) based additive manufacturing (AM) or 3D printing technology. This new Area Printing technology greatly enhances the quality and productivity of metal additive manufacturing processes. The ideal candidate should have a strong background in additive manufacturing, with expertise in CFD modeling, experimental techniques, and laser powder bed fusion (LPBF).

Responsibilities: 

• Perform CFD simulations to optimize gas flow uniformity, minimize powder entrainment, enhance gas flow efficiency in removing condensation, and study laser-powder interactions in novel Area Printing systems.
• Design and execute experiments/prints to validate simulations and improve printed material quality.
• Develop and implement new methodologies and technologies, e.g., in-situ monitoring, process automation, etc., to improve the area printing process and printed material properties by evaluating porosity and mechanical properties.
• Work closely with additive manufacturing, process, and materials engineers to develop integrated solutions and support technology scale-up efforts.
• Stay updated with industry trends, emerging research, and advancements in additive manufacturing and contribute to intellectual property development.

Requirements:

• Master’s degree in mechanical engineering, materials engineering, materials science, or related field.
• 3+ years of proven experience in CFD modeling, with applications in multiphase flow, heat transfer, and turbulence modeling in additive manufacturing.
• Proficiency in CFD and FEA software such as Ansys Fluent, OpenFOAM, or SolidWorks Flow Simulation.
• Proficiency at scripting in languages such as Python or Matlab.
• Strong experimental skills with a track record of designing and conducting complex experiments, including print preparation, operation, and in-situ monitoring.
• Proficiency in additive manufacturing technologies such as laser powder bed fusion.
• Familiarity with thermo-mechanical modeling and its application in additive manufacturing.
• Excellent communication, analytical, and problem-solving skills, with keen attention to detail.
• Ability to work independently and as part of a team in a fast-paced environment.
• Work effectively in a cross-functional and multidisciplinary team environment.
• Travel up to 10%. 

Preferred Qualifications:

• Ph.D. in mechanical engineering, materials engineering, materials science, or related field.
• 2+ years of experience in industry, national labs, or research institutes, focusing on additive manufacturing R&D.
• R&D experience with modeling cross-bed flow and laser-powder interactions in LPBF systems.
• R&D experience with thermo-mechanical modeling applied to additive manufacturing processes.
• Proficiency at creating subroutines in languages like C++ or Fortran to supplement numerical models.