Additive Manufacturing Engineer, Fused Deposition Modeling

General Atomics Aeronautical Systems, Inc. (GA-ASI), an affiliate of General Atomics, is a world leader in proven, reliable remotely piloted aircraft and tactical reconnaissance radars, as well as advanced high-resolution surveillance systems.

We have an exciting opportunity for a dynamic and proactive Plastics/Polymer Additive Manufacturing Engineer in our Additive Manufacturing (AM) department located in Poway, CA. This onsite position will support the Fused Deposition Modeling (FDM/FFF) AM production operation team at GA-ASI in design (DfAM), process and parts qualification, first article, production, tests, technology assessment and development.

Although it is part of the Aircraft Systems Manufacturing group, this position will be a key interface role between various other internal and external stakeholders such as Design engineering, Materials & Processes engineering, Programs management, and Supply Chains as serving as subject matter expert (SME) to help integrate plastics/polymer FDM/FFF AM into GA-ASI's products and processes, as part of the Center of Excellence mission statement of the AM group. This position will provide the candidate with a critical role opportunity into the growth of AM at GA-ASI.

DUTES AND RESPONSIBILITIES:

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• Subject Matter Expert (SME) on industrial FDM/FFF AM and key interface with key engineering stakeholders such as design, materials, process and quality.
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• DfAM FDM/FFF SME and main point contact for internal stakeholders, to support design engineering's learning and teaching of DfAM specific to FDM/FFF AM, as well as supporting software tool assessment and testing to support manufacturing and engineering AM efforts.
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• Support with plastics/polymer AM suppliers/contract manufacturers qualification, relationships and visits
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• Responsible for industrial production-focused AM process development, qualification, implementation, and continuous improvement to enhance Quality / Yield, reduce Cost, and improve Productivity / Schedule.
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• Initiate and lead lean manufacturing process improvement projects.
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• Support and lead the planning and implementation of AM (incl. post-processing) equipment and associated processes and safety.
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• Identify and assist in addressing safety issues on the manufacturing floor.
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• Support manufacturing production planning and coordination, execution and operations process development.
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• Provide production support to AM operation team (technicians and production lead).
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• Document manufacturing processes and assembly work instructions in conjunction with T&O Planning.
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• Assist and drive AM quality and inspection process improvement related to plastics AM.
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• Support with internal needs for AM CAD designs to assist with AM group operations.
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• Disposition non-conforming parts, identify root cause analysis, and implement corrective and/or preventive action to reduce scrap and rework.
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• FDM/FFF AM-related project plan development and management.
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• Participation in internal and external AM group representation (e.g. conferences, collaboration groups, executive management reviews, etc.)
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• Collaborate with Design Engineering during design release, application development, prototyping and first article manufacturing of FDM/FFF components.
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• Support and lead technology and material exploration, assessment and incubation.
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We recognize and appreciate the value and contributions of individuals with diverse backgrounds and experiences and welcome all qualified individuals to apply.

Job Qualifications:

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• Typically requires a bachelors degree, masters degree or PhD in engineering or a related technical discipline from an accredited institution and progressive engineering experience as follows; four or more years of experience with a bachelors degree or two or more years of experience with a masters degree. May substitute equivalent engineering experience in lieu of education.
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• Extensive experience with Fused Deposition Modeling (FDM/FFF) AM technologies in a production industrial environment. Direct experience with Stratasys production printers and their associated file preparation software is highly desired.
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• Experience in Aviation/Aerospace/Unmanned Aerial Systems industry is desired, but not necessary.
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• Experience with AM applications specific to Aviation/Aerospace/Unmanned Aerial Systems is desired, but not necessary.
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• Experience with the entire FDM/FFF AM part production workflow from business considerations, design release and review, pre-print considerations and planning (incl. support strategy, file preparations, etc.), printing, post-processing, qualification, and inspection process.
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• Direct experience with FDM/FFF-associated post-processing equipment and safety best practices and PPE.
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• Working knowledge of other adjacent FDM/FFF and/or polymer AM technologies, and their associated characteristics and applicability/use cases.
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• Expertise in Design for Additive Manufacturing (DfAM), specifically related to FDM/FFF AM. Ability to demonstrate/provide examples of designs achieved. This assumes proficiency with at least one major CAD platform (e.g. Siemens Nx, PTC CREO, CATIA, ProE, etc.)
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• Experience with major FDM/FFF-related AM suppliers (service bureaus, contract manufacturers, materials and hardware providers, software providers, etc.)
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• Background knowledge of conventional manufacturing processes (complementary to FDM/FFF AM, such as CNC machining, bonding, coating, plating, infiltrating, painting, injection molding, etc.) is a plus.
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• Clearly and effectively communicate both verbally and in written form to both technical and non-technical audiences, especially regarding manufacturing processes, engineering issues and proposed changes, and quality issues and dispositions.
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• Ability to form and foster rich AM networking and keep engaged.
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• Experience with Microsoft Office PowerPoint, Project, Excel and Visio.
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• Experience with SAP systems is an advantage.
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• Must be able to work both independently and in a team environment.
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• Must be self-driven, like to innovate, and want to learn more and more.
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• Must be able to obtain and maintain a DoD Security Clearance.
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• Ability to influence others, develop a plan and rally a team around it, lead small team.
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• Able to work extended hours and travel occasionally as required.
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Salary:$81,080 - $141,650