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Senior Additive Manufacturing Engineer
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Senior Additive Manufacturing Engineer (WAAM) – Ampthill
Salary: Circa £57,000 (DOE)
About the Role
The Manufacturing Engineer (WAAM Bias) designs, implements, and optimizes large-scale Wire Arc Additive Manufacturing (WAAM) processes for aerospace components. This role focuses on developing processes for complex, near-net-shape metallic structures, ensuring strict compliance with aviation quality and safety standards from design to production.
Key Responsibilities
Process Development
- Establish, validate, and optimize WAAM deposition parameters (current, voltage, travel speed, shielding gas flow).
- Work with aerospace alloys such as Titanium, Inconel, and Aluminium to ensure high-quality outcomes.
Path Planning & Simulation
- Utilize specialized additive manufacturing software to generate, simulate, and optimize multi-axis robotic/CNC deposition paths.
- Prevent collisions and minimize thermal distortion.
Thermal Management
- Develop and execute thermal control strategies, including inter-pass temperature monitoring and in-process cooling.
- Manage residual stress and microstructural integrity.
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New Product Introduction (NPI)
- Lead the transformation of aerospace CAD models into WAAM-optimized, near-net-shape geometries for post-process machining.
Equipment Integration
- Program, configure, and maintain integrated WAAM cells (e.g., ABB robotics and Fronius power sources).
- Manage environmental enclosures and related automation systems.
Quality & Qualification
- Ensure all processes meet aerospace standards such as AS9100 and emerging additive manufacturing regulations (e.g., ASTM F42, SAE AMS7039).
Qualifications & Experience
Technical Skills & Experience
- Strong working knowledge of:
- CNC machining (turning and milling up to 5-axis)
- WAAM / Additive Manufacturing techniques
- CAM software (preferably HyperMill experience is an advantage)
- Experience with Lean Manufacturing, Six Sigma, and quality improvement tools.
- Proficiency in CAD software for generating 2D technical drawings.
- Solid understanding of MRP systems and experience managing Bill of Materials (BOMs) and routings in SAP (or similar ERP systems).
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Soft Skills & Mindset
- Ability to drive cultural and process change for improved efficiency and quality.
- Highly collaborative with a ** passion for continuous improvement**.
Qualifications
- Degree/Master’s in Manufacturing, Materials Science, Aerospace, or Mechanical Engineering.
- PhD or research focus heavily centered on WAAM/DED is highly desirable.
Industry Experience
- Minimum 3 years’ hands-on experience in Directed Energy Deposition (DED), specifically Wire Arc Additive Manufacturing, in a high-integrity engineering environment.
- Essential practical background in aerospace, space-launch systems, or defence manufacturing.
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