Process Development Engineer

Process Development Engineer

MELD Manufacturing - Virginia (Christiansburg)

Position Summary: MELD is seeking two process development engineers. The Process Development Engineer is responsible for leading internal R&D (IRAD) and customer-funded projects to develop, optimize, and validate MELD manufacturing processes. This role drives process innovation from concept through qualification by designing and executing process development activities, analyzing results, and establishing robust process specifications. The engineer collaborates closely with Materials & Processes, Quality, Engineering, and Manufacturing teams to transition developed processes into production, providing the technical data and documentation required for implementation by Quality and Production team. The position also supports proposal and state of work development, project management, technical documentation, and continuous improvement initiatives while advancing MELD’s manufacturing capabilities. Primary Duties and Responsibilities: Lead MELD process development, optimization, and validation of manufacturing new materials, material combinations, repair applications, and novel manufacturing solutions. Lead prototyping, process parameters tuning, and thermo-mechanical processing (TMP) studies for steels, copper, magnesium, aluminum, titanium, nickel, and other alloys. Develop, evaluate, and optimize processing parameters to deposit complex components, achieve target material performance, and optimize manufacturing efficiency. Analyze experimental data and communicate technical findings and recommendations to internal stakeholders. Serve as a technical expert in MELD process technology through hands-on operation, programming, troubleshooting, and continuous improvement of MELD equipment, tooling, machine hardware and software. Design, execute, and lead experimental process development programs using metallurgical principles, statistical methods, and empirical engineering approaches. Support manufacturing operations by investigating process-related issues, identifying root causes, and implementing robust process improvements. Collaborate with internal and external stakeholders to develop new applications, qualify processes, and provide technical feedback for production implementation. Support business development through proposal preparation, technical volume writing, Statement of Work (SOW) development, project planning, and technical leadership of assigned projects. Support materials characterization and metallurgical laboratory activities, including heat treatment optimization, sample prep, mechanical testing, microstructural characterization, and failure analysis as required. Monitor advancements in metallurgy, materials science, solid-state joining/manufacturing, and additive manufacturing technologies, identifying opportunities to incorporate emerging innovations into MELD products and manufacturing capabilities. Collaborate with M&P team and other departments (Quality, Engineering, Manufacturing, Sales & Applications, and Production teams) to execute projects on schedule and meet technical objectives. Prepare technical documentation including test plans, process specifications, standard operating procedures, technical reports, and customer deliverables. Document details, follow established processes, implement new processes to ensure quality, and create technical reports. Present project status, technical results, and recommendations to management and customers. Lead project management activities (planning, execution, timeline and budget tracking, reporting, etc.) of assigned projects including budget management Promote robust engineering practices, process standardization, continuous improvement, and a strong safety culture throughout research, development, and production operations, including participation in 6S Lean initiatives. Contribute to the generation, documentation, and protection of MELD intellectual property through invention disclosures, patents, and trade secrets.

Required Qualifications:

Qualifications: Minimum bachelor’s degree in Materials Science & Engineering, Metallurgy, Mechanical Engineering, Manufacturing engineering or related fields. Minimum 2 years of industry experience in additive manufacturing, metallurgy, processing, or manufacturing. 4+ years preferred. Experienced with R&D processes with strong problem-solving skills Detail orientated and ability to document details and follow processes Effective verbal and written communication skills Ability to develop technical documentation Ability to work independently and as part of a team while managing multiple priorities. Experience with friction stir welding, solid-state joining, MELD or other advanced additive processes are preferred.

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