Additive Manufacturing Process Engineer (Onsite)

Additive Manufacturing (Am) Process Engineer

The Collins Aerospace Additive Design and Manufacturing (ADaM) team is seeking an Additive Manufacturing (AM) Process Engineer for its Monroe, NC Additive Manufacturing facility. In this highly technical and process-focused role, you will develop, implement, validate, and sustain additive manufacturing processes to ensure stable, capable, and controlled production aligned with SPQDC objectives. You will define and maintain process architecture within MES, lead process qualifications, and create standardized process templates that guide production execution. This role is central to ensuring process capability, compliance, and manufacturing readiness.

The ideal candidate is a hands-on engineer with deep knowledge of laser powder bed fusion (LPBF) process behavior, process control, material–process interactions, and manufacturing system integration. They thrive in an engineering-driven environment, are detail-oriented, and are passionate about building robust manufacturing processes, improving capability, and driving repeatable production performance.

This position is onsite in Monroe, NC.

What You Will Do:

• Own MES usage architecture for AM processes, including standard operations, workflows, and process plan setup; define how manufacturing processes are configured and executed across the production system.
• Define and maintain AM process parameters, specifications, and controlled process documentation (WIs, traveler elements, workflow logic).
• Execute and document IQ, OQ, and MQ qualifications for equipment and processes, ensuring validated, compliant, and traceable process baselines.
• Lead SPC tracking, process capability analysis, and performance monitoring to assess process health and drive data-based improvements.
• Support production builds by troubleshooting process issues, validating parameter sets, and providing technical guidance to Operations and Quality.
• Develop build layouts, optimized manufacturing processes, and cell-level process designs to improve efficiency, robustness, and throughput.
• Generate and maintain Golden Files as part of NPI Gate 4 activities to establish frozen, qualified process configurations.
• Lead PPAP-related process inputs including Control Plans, PFMEAs, process flow diagrams, and validation evidence.
• Create standardized, reusable process templates that guide future production execution and enable efficient configuration by the Project Engineer.
• Collaborate with Materials Scientists to ensure process parameters and material behaviors are correctly linked within MES and reflected in process performance.
• Work closely with Quality Engineering on nonconformance investigations, root cause analysis, corrective actions, and integration of quality controls into the QMS/MES.
• Provide technical input to Operations, supporting work instructions, technician readiness, build setups, and troubleshooting of process-related disruptions.
• Align with the Digital Systems & SIOP Lead to integrate process logic, SPC data, and system automation into digital tools and MES workflows.
• Drive continuous improvement projects to enhance process capability, yield, stability, and alignment with SPQDC objectives.
• Travel up to 10%.

Qualifications You Must Have:

• Typically requires a University Degree and minimum 5 years prior relevant experience or an Advanced Degree in a related field and minimum 3 years of experience
• 3+ years of experience with laser powder bed fusion metal additive manufacturing, including process parameters, process controls, and machine functionality (laser behavior, build environment, powder handling, etc.).
• 3+ years of experience developing, validating, or sustaining manufacturing processes, including process documentation, workflow control, and troubleshooting processes.
• 2+ years of experience with MES, process architecture, or digital manufacturing workflows (e.g., defining steps, routings, or parameter-driven operations).

Qualifications We Prefer:

• Master's degree in science, engineering, materials science, or other related field.
• Experience with process validation activities (IQ/OQ/MQ), PFMEA, Control Plans, or PPAP-related documentation.
• Familiarity with AM or special process specifications and standards (e.g., AMS, NASA-STD, customer-specific process requirements).
• Hands-on experience with SPC tools, process-health monitoring, or development of controlled parameter sets.
• Experience with traditional manufacturing processes involving metals, including troubleshooting process variability.
• Strong analytical and problem-solving skills, with the ability to interpret data and drive process capability improvements.
• Ability to work effectively in a cross-functional engineering environment and communicate technical information clearly.

Some of our competitive benefits package includes:

• Medical, dental, and vision insurance
• Three weeks of vacation for newly hired employees
• Generous 401(k) plan that includes employer matching funds and separate employer retirement contribution, including a Lifetime Income Strategy option
• Tuition reimbursement program
• Student Loan Repayment Program
• Life insurance and disability coverage
• Optional coverages you can buy pet insurance, home and auto insurance, additional life and accident insurance, critical illness insurance, group legal, ID theft protection
• Birth, adoption, parental leave benefits
• Ovia Health, fertility, and family planning
• Adoption Assistance
• Autism Benefit
• Employee Assistance Plan, including up to 10 free counseling sessions
• Healthy You Incentives, wellness rewards program
• Doctor on Demand, virtual doctor visits
• Bright Horizons, child and elder care services
• Teladoc Medical Experts, second opinion program
• And more!