Job Details

Job Summary

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 self-driven entry-level Additive Manufacturing (AM) Engineer in our AM department located in Poway, CA.

This position will occupy a strategic role in the growth of AM at GA-ASI, by supporting current and next generation UAS platform development leveraging a variety of AM technologies and materials. This position will specifically work on metal laser powder-bed fusion AM-related projects and manufacturing operations to support flight-ready part manufacturing for a wide range of platforms/programs and its stakeholders. Although this role will predominantly support metal AM, it will also be closely involved with other modalities of AM such as FDM/FFF, SLS polymer/composites, DED and other tooling technologies. This role will provide both AM technology and materials subject matter expertise towards new application development, as well as provide support for the manufacturing daily operations. This role will be driving simultaneously several projects related to new AM applications, IRAD, process improvement, equipment onboarding and maintenance, communication, training program, as well as complex production-related projects while providing periodical updates to the working teams and to the leadership. This role will have a significant component of outward-facing interactions with various engineering, quality, and program stakeholder teams across GA-ASI.

Although it is part of the Aircraft Systems Manufacturing division, this position will have interactions between various other internal and external stakeholders such as Quality Engineering, Materials & Processes Engineering, Programs Management, Advanced Programs, Design Engineering, Service and Supply Chain management, as well as external suppliers. It will also interface and work closely with multiple programs within the greater GA&A company (other divisions of GA). This position will be key to help grow and improve our AM flight hardware production operations, and integrate AM applications into GA-ASI's products and processes, as part of the Center of Excellence mission statement. This position will provide the entry-level candidate with an opportunity to be at the forefront and become a key contributor to the growth of metals, polymer, tooling and composites AM at GA-ASI.

DUTES AND RESPONSIBILITIES:

• Become Subject Matter Expert (SME) on metal Laser Powder Bed Fusion (LPBF) primarily, and over time, on other AM modalities. Technologies of interest to be supported by this role could include (but not limited to): Fused Deposition Modeling - FDM, Selective Laser Sintering - SLS, Laser Powder Bed Fusion - LPBF, Binder Jet (sand), LSAM/BAAM, Direct Energy Deposition - Wired (DED-W), DAPS™, SLA, DLP, MJF, ECAM, and other AM technologies.
• Working hand-in-hand with the metal LPBF manufacturing engineer in support of operations and new application development.
• Responsible for AM rapid development and rate production manufacturing workflow, qualification, implementation, and continuous improvement to enhance Quality / Yield, reduce Cost, and improve Productivity / Schedule. Initiate and lead lean manufacturing process improvement projects.
• Support manufacturing production planning and coordination, execution and operations process development.
• Support and lead the planning and implementation of AM (incl. post-processing) equipment and associated processes and safety.
• Identify and assist in addressing safety issues on the manufacturing floor.
• Provide production support to AM technicians, assemblers and leads.
• Document manufacturing processes and assembly work instructions in conjunction with support staff.
• Revision of AM specification documentation with key Materials & Process stakeholders.
• Review engineering drawings, and provide expertise on metal LPBF during engineering review processes.
• Learn other AM modalities processes, materials and application space towards supporting new application development through design for AM, manufacturing process optimization and testing.
• Key interface with engineering stakeholders such as design, materials, process and quality.
• Support and lead new technology exploration, assessment and incubation for metal and non-metal AM.
• Work closely with DfAM engineering on manufacturing/production operations, and assist with design engineering's knowledge transfer and teaching efforts.
• Disposition non-conforming parts, identify root cause analysis, and implement corrective and/or preventive action to reduce scrap and rework.
• Participate in metal AM-related plan development and management for internal R&D projects.
• Participation in internal and external AM group representation (e.g. conferences, collaboration groups, executive management reviews, etc.) as relevant and applicable.
• Collaborate with Design Engineering during development, prototype and first article manufacturing.
• Support with AM supplier onboarding, qualification, relationship building and visits.
• Support in growth strategy of metal AM within AM department and across GA divisions.

We recognize and appreciate the value and contributions of individuals with diverse backgrounds and experiences and welcome all qualified individuals to apply.

Job Qualifications

• Typically requires a bachelors or masters degree in engineering or a related technical discipline from an accredited institution and two or more years of engineering experience with a bachelors degree. May substitute equivalent engineering experience in lieu of education.
• Direct experience with industrial-class production additive manufacturing technologies, processes and applications. Defense-related manufacturing environment is highly desired.
• Hands-on experience with Laser Powder Bed Fusion (LPBF) technologies metal AM as a designer, and as a user of the LPBF to manufacture industrial parts. Complementary hands-on experience with design and printing operations with other AM modalities (metal and non-metals) are also very valuable.
• Experience with the entire AM workflow from business considerations, design, pre-print considerations and planning, printing, post-processing and qualification process. Special considerations for metal LPBF technologies.
• Experience with metal LPBF and/or other industrial AM printers and associated post-processing equipment and safety procedure
• Working knowledge of most key AM technologies, and their associated characteristics and applicability/use cases for defense/aviation/aerospace is highly desired.
• Experience in Design for Additive Manufacturing (DfAM).
• Experience dealing with AM suppliers (service bureaus, materials and hardware providers, software providers, etc.)
• Background knowledge of conventional manufacturing processes (complementary to metal AM, such as CNC machining, casting, welding, metrology, assembly, bonding, etc.)
• 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.
• Ability to form and foster rich AM networking and keep engaged.
• Experience with Microsoft Office PowerPoint, Project, Excel and Visio.
• Experience with MRP systems is an advantage, (e.g. SAP or MTO/WDS.)
• Experience with PLM systems is an advantage (e.g. Teamcenter, Windchill, etc.)
• Must be able to work both independently and in a team environment.
• Must be self-driven, like to innovate, and want to learn more and more.
• Ability to influence others, develop a plan and rally a team around it, lead small team.
• Able to work extended hours and travel occasionally as required.
• Ability to obtain and/or maintain a security clearance is required.