Lockheed Martin
Senior Additive Manufacturing Engineer (WAAM)
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Manufacturing Engineer (WAAM Bias) – Production Operations Engineering
About the Role
Join our Production Operations Engineering Team as a Manufacturing Engineer (WAAM Bias)!
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 from design to production, ensuring strict compliance with aviation quality and safety standards.
Key Responsibilities
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Process Development: Establish, validate, and optimize WAAM deposition parameters (current, voltage, travel speed, shielding gas flow) for aerospace alloys, including Titanium, Inconel, and Aluminium.
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Path Planning & Simulation: Utilize specialized additive software to generate, simulate, and optimize multi-axis robot/CNC deposition paths, preventing collisions and minimizing thermal distortion.
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Thermal Management: Design and execute thermal control strategies, including inter-pass temperature monitoring and in-process cooling, to 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, ready for post-process machining.
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Equipment Integration: Program, configure, and maintain integrated WAAM cells, including:
- Robotic manipulators (ABB)
- Power sources (Fronius)
- Environmental enclosures
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Quality & Qualification: Ensure all manufacturing processes conform to:
- AS9100 (aerospace quality standards)
- Emerging additive manufacturing regulations (ASTM F42, SAE AMS7039)
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Key Skills & Competencies
- Additive Software: High proficiency in WAAM-specific slicing and path-generation software.
- Robotics & Automation: Ability to program multi-axis industrial robots and integrate sensor feedback loops for real-time process monitoring.
- Aerospace Metallurgy: Deep understanding of:
- Solidification mechanics
- Phase transformations
- Defect generation (porosity, cracking in wire-fed arc deposition)
- Subtractive Integration: Strong knowledge of how WAAM near-net shapes interface with subsequent precision CNC machining.
- Root Cause Analysis: Mastery of problem-solving frameworks (8D, FMEA, 5 Whys) for troubleshooting deposition anomalies.
Required Qualifications & Experience
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Technical Knowledge & Hands-On Skills:
- Good working knowledge of CNC Machining (turning and milling, up to 5-axis) with experience in CAM software or WAAM/Additive Manufacturing.
- Familiarity with Lean Manufacturing, Six Sigma, and quality improvement tools.
- Experience with CAD software for generating 2D technical drawings.
- Solid understanding of MRP systems and experience managing BOMs and routings in SAP (or similar ERP systems).
- HyperMill CAM experience is a significant advantage.
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Cultural & Process Change:
- Proven ability to drive efficiency improvements and enhance quality.
- Collaborative mindset and passion for continuous improvement.
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Education:
- Degree or Master’s in Manufacturing, Materials Science, Aerospace, or Mechanical Engineering.
- PhD or research focus heavily centered on WAAM/DED is highly desirable.
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Experience:
- Minimum 3 years of hands-on experience in Directed Energy Deposition (DED), specifically Wire Arc Additive Manufacturing.
- Must have worked in a high-integrity engineering environment.
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Industry Background:
- Required: Prior experience in aerospace, space-launch systems, or defense manufacturing.
Business Environment at Lockheed Martin (UK) Ampthill
Lockheed Martin (UK) Ampthill is a dynamic, rapidly evolving division of the Lockheed Martin Corporation, serving both domestic and international customers across:
- Platform Integration
- Ground-Based Air Defence
- Special Projects
- Weapons
We’re seeking talented individuals to contribute to
- A challenging career path
- Excellent work-life balance (4-day week, Monday-Thursday) and flexible working.
- Innovative projects with leading-edge technology.
Lockheed Martin upholds equal opportunity principles, fostering a culture of integrity, respect, and exceptional performance. We embrace diversity, leveraging unique talents and experiences to drive innovation and deliver superior solutions.
If you believe your skills and perspectives could strengthen our team, we encourage you to apply—even if your experience doesn’t fully align with every requirement. Accommodations are available throughout the recruitment process. Contact recruitment@global.lmco.com for support.
Equal Opportunities Commitment
Lockheed Martin is dedicated to an inclusive recruitment process, providing reasonable adjustments for applicants as needed.
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