Additive Manufacturing Systems Lead Engineer

Terrestrial X Inc. is seeking an Additive Manufacturing Systems Lead Engineer to drive the design, development, optimization, and deployment of advanced 3D printing and hybrid manufacturing systems for mission-critical applications in aerospace, defense, energy, nuclear, and medical sectors. This senior technical leadership role combines deep expertise in metal and polymer additive manufacturing (AM), equipment design and integration, process engineering, and regulated-industry compliance to deliver production-ready solutions from concept through qualification.

You will serve as the primary technical authority on AM system performance, parameter development, and digital workflow integration, while mentoring Canadian staff and ensuring all outputs meet AS9100, NADCAP, ITAR, ISO 13485, and nuclear QA standards.

Key Responsibilities1. Additive Manufacturing Process Leadership

• Lead end-to-end execution of customer AM projects using WAAM, L-PBF, DED, FDM, SLA, and hybrid AM–CNC workflows.
• Develop and validate build strategies, toolpaths, deposition parameters, support structures, and thermal management protocols for exotic alloys, high-performance polymers, and composites.
• Perform real-time defect diagnosis (porosity, cracking, warping, residual stress) and root-cause analysis using metallurgical, thermal, and digital twinning tools.
• Optimize powder behavior, laser/arc dynamics, and post-processing (HIP, heat treatment, machining) for repeatability and qualification.

2. Equipment Design & System Integration

• Design, specify, and integrate large-format metal AM platforms, robotic deposition systems, and multi-axis hybrid cells (AM + CNC).
• Lead equipment commissioning, calibration, and performance verification for new or upgraded 3D printing systems.
• Develop digital threads for traceability, including sensor integration, in-process monitoring, and closed-loop control.
• Support R&D into next-generation platforms, including mobile/deployable units (e.g., MANTIS) and automated material handling.

3. Design for Additive Manufacturing (DfAM) & CAD Workflow

• Conduct CAD model review, topology optimization, and DfAM for flight-critical, energy-critical, and medical components.
• Generate flat-pattern development, build orientation analysis, and support minimization strategies.
• Collaborate with customers on design iteration, feasibility studies, and qualification packages.

4. Materials Science & Process Development

• Select and qualify AM-grade materials (titanium, Inconel, stainless, tool steels, PEEK, ULTEM, etc.) for regulated applications.
• Perform mechanical testing, microstructural analysis, and metrology verification (CMM, CT scanning, laser profiling).
• Lead material and process patent development in high-temperature, nuclear-approved, or ITAR-controlled domains.

5. Regulated Industry Compliance & Quality Assurance

• Ensure full compliance with AS9100, NADCAP, ITAR, Controlled Goods, ISO 13485, and nuclear QA frameworks.
• Author technical documentation, work instructions, and qualification reports for customer and regulatory audits.
• Manage export-control, secure data handling, and NATO-aligned security protocols.

6. Training & Knowledge Transfer

• Mentor and train Canadian technicians, apprentices, and engineers in advanced AM operations, safety, and best practices.
• Develop standard operating procedures (SOPs), training modules, and how-to content (videos, guides, workshops).
• Build long-term domestic capability in metal AM, WAAM, and defense-grade manufacturing.

7. Customer & Project Leadership

• Act as technical liaison in client design reviews, factory visits, and international engagements.
• Oversee quoting, scoping, timeline management, and on-time delivery of AM prototypes and production runs.
• Deliver technical presentations, data packages, and progress reports to stakeholders.

Required Qualifications Education

• College-level diploma or certificate in engineering, materials science, or related technical field
• Strong foundation in economics and manufacturing costing

Experience

• 10–12 years of progressive, hands-on experience in advanced manufacturing and 3D printing
• 5+ years in senior application engineering roles with FDM, high-temperature AM, and filament-based systems
• 3+ years leading technical teams across multi-country regions (e.g., EMEA)
• Deep expertise in:
• WAAM, L-PBF, DED, FDM, SLA, hybrid AM–CNC
• DfAM, CAD interpretation, materials selection, prototyping
• Troubleshooting AM defects and process optimization
• QA/QC in regulated environments (AS9100, NADCAP, ITAR, ISO 13485, nuclear)
• Proven track record in:
• Customer-facing technical support and training
• Quoting, project management, and cross-functional collaboration
• Content creation (documentation, videos, workshops)

Certifications & Security

• Controlled Goods Program and ITAR compliance clearance required
• Must be a citizen of a NATO member or NATO-aligned country

Technical Skills

• Advanced proficiency in CAD (SolidWorks, NX), slicers, and simulation tools
• Expertise in metrology (CMM, 3D scanning), mechanical testing, and microstructure analysis
• Knowledge of robotic systems, automation, and digital twinning

Soft Skills

• Exceptional technical communication (written and verbal) in English
• Fluency in German (required for customer and partner engagement)
• Strong project leadership, problem-solving, and mentoring abilities

What We Offer

• Competitive compensation: $200,000 CAD/year + project success bonuses
• Comprehensive benefits:
• Extended medical, dental, and disability insurance
• 25 paid vacation days + 9.2% vacation pay
• Opportunity to shape Canada's advanced manufacturing future
• Work with cutting-edge AM systems in defense, aerospace, and energy
• Direct impact on national industrial capability and workforce development

Security & Compliance Note

Due to the sensitive nature of our work in defense, aerospace, and nuclear sectors, all candidates must:

• Originate from a NATO or NATO-aligned nation
• Be eligible for Controlled Goods and ITAR registration
• Adhere to strict export-control and secure information protocols

Must be able to enter USA for travel. Must pass local and international criminal record checks, and PEP screening. Must possess or be able to obtain NATO/Government security clearance.