What are the responsibilities and job description for the Additive Manufacturing Engineer, Fused Deposition Modeling position at General Atomics Aeronautical Systems?
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 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:
Job Qualifications
Salary range: 81,080 - 141,650
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:
- Subject Matter Expert (SME) on industrial FDM/FFF AM and key interface with key engineering stakeholders such as design, materials, process and quality.
- 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.
- Support with plastics/polymer AM suppliers/contract manufacturers qualification, relationships and visits
- Responsible for industrial production-focused AM process development, qualification, implementation, and continuous improvement to enhance Quality / Yield, reduce Cost, and improve Productivity / Schedule.
- Initiate and lead lean manufacturing process improvement projects.
- 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.
- Support manufacturing production planning and coordination, execution and operations process development.
- Provide production support to AM operation team (technicians and production lead).
- Document manufacturing processes and assembly work instructions in conjunction with T&O Planning.
- Assist and drive AM quality and inspection process improvement related to plastics AM.
- Support with internal needs for AM CAD designs to assist with AM group operations.
- Disposition non-conforming parts, identify root cause analysis, and implement corrective and/or preventive action to reduce scrap and rework.
- FDM/FFF AM-related project plan development and management.
- Participation in internal and external AM group representation (e.g. conferences, collaboration groups, executive management reviews, etc.)
- Collaborate with Design Engineering during design release, application development, prototyping and first article manufacturing of FDM/FFF components.
- Support and lead technology and material exploration, assessment and incubation.
Job Qualifications
- 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.
- 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.
- Experience in Aviation/Aerospace/Unmanned Aerial Systems industry is desired, but not necessary.
- Experience with AM applications specific to Aviation/Aerospace/Unmanned Aerial Systems is desired, but not necessary.
- 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.
- Direct experience with FDM/FFF-associated post-processing equipment and safety best practices and PPE.
- Working knowledge of other adjacent FDM/FFF and/or polymer AM technologies, and their associated characteristics and applicability/use cases.
- 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.)
- Experience with major FDM/FFF-related AM suppliers (service bureaus, contract manufacturers, materials and hardware providers, software providers, etc.)
- 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.
- 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 SAP systems is an advantage.
- 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.
- Must be able to obtain and maintain a DoD Security Clearance.
- 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.
Salary range: 81,080 - 141,650
