Process Lead Engineer for Additive Manufacturing

Honda Aero, LLC.•Burlington, NC

10d

About The Position

Honda has a clear vision for the future, and it’s a joyful one. We are looking for individuals with the skills, courage, persistence, and dreams that will help us reach our future-focused goals. At our core is innovation. Honda is constantly innovating and developing solutions to drive our business with record success. We strive to be a company that serves as a source of “power” that supports people around the world who are trying to do things based on their own initiative and that helps people expand their own potential. To this end, Honda strives to realize “the joy and freedom of mobility” by developing new technologies and an innovative approach to achieve a “zero environmental footprint.” We are looking for qualified individuals with diverse backgrounds, experiences, continuous improvement values, and a strong work ethic to join our team. If your goals and values align with Honda’s, we want you to join our team to Bring the Future! Job Purpose The Additive Manufacturing (AM) Process Lead will drive the development, qualification, and continuous improvement of metal LPBF (Laser Powder Bed Fusion) processes for aero‑engine components. This position requires strong hands‑on expertise with LPBF equipment, including machine operation, calibration, tuning, and maintenance, as well as experience in parameter development and process optimization. The Process Lead will support supplier readiness, evaluate/develop Machine/Process Qualification activities, and establish production‑ready AM and post‑processing workflows. The role requires close coordination with Design, Materials and Quality to meet the milestones for component development, qualification, certification, and future production. Keywords: LPBF, process development DOE, machine calibration, supplier development, qualification/certification/production, cross‑functional contribution, problem solving

Requirements

Bachelor’s degree in Mechanical Engineering, Materials Engineering, Aerospace Engineering, Manufacturing Engineering, or equivalent experience.
Hands‑on experience (5+ years) with metal LPBF EOS M400-4 or M290 systems, including build setup, operation, powder handling, and troubleshooting.
Capability to perform LPBF machine tuning (e.g., optical‑related adjustments such as laser alignment, scan‑field/beam‑offset checks, Z‑axis/recoater verification).
LPBF parameter development, including DOE‑based optimization (e.g., diagnosing root causes related to laser performance, recoating behaviour, powder spreading, thermal distortion, scan strategy).
Ability to maintain a safe, clean, and controlled AM work environment.
Ability to interpret and create engineering drawings, including GD&T understanding, tolerances, and manufacturability considerations.
Strong practical engineering skills and the ability to independently perform hands‑on work on LPBF equipment and related tools.
Solid analytical skills to support test planning, data interpretation, and preparation of technical reports.
Ability to organize and execute assigned project tasks, track schedules, and contribute to issue resolution in cross‑functional teams.
Ability to write clear, structured engineering documents and communicate technical content effectively.
Ability to manage multiple tasks, maintain detailed records, and ensure process traceability.
Effective communication and collaboration across international and cross‑functional teams.

Nice To Haves

Powder quality evaluation and NDT/CT/inspection workflows.
In‑situ monitoring/process simulation or thermal/optical process data.
Participating in equipment installation, SAT/FAT, or facility preparation.
Supporting supplier technical assessments or capability reviews.
Knowledge of aerospace quality frameworks or certification concepts: AS9100 FAA Certification / AC35.15-3
Familiarity with AM build preparation software.
Familiarity with internal calibration and verification procedures for AM machine.
Experience with Material Qualification or Part Qualification.

Responsibilities

Lead LPBF build setup, execution, and troubleshooting; maintain detailed and traceable build records.
Perform machine calibration and tuning, including laser alignment, scan field or beam offset adjustments, Z‑axis checks, and recoater verification.
Develop and refine LPBF parameter sets using DOE and data‑driven approaches.
Conduct engineering tests and verification builds using the PDCA cycle.
Support in‑situ monitoring/simulation data interpretation and correlation with part quality.
Analyse build failures systematically and implement corrective/preventive actions.
Operate auxiliary equipment such as EDM, heat treatment furnace, CNC machines, and metrology equipment as needed.
Review 2D and/or 3D models and provide manufacturability feedback to design engineers in the U.S. (US) and Japan (JP).
Oversee powder management, powder characterization, and lot traceability.
Maintain equipment health through preventive maintenance and performance monitoring.
Create and maintain Process Control Documents (PCDs) such as quality control plans, work instructions etc.
Collaborate with regulatory and industrial groups when required (e.g., FAA/EASA, ASTM, SAE, America Makes).
Adhere to AMS 7003 and AMS 7032 specifications for execution and documentation.
Lead technical evaluations for LPBF and post‑processing capabilities.
Support the creation and execution of qualification tests, including parameter window establishment and production readiness assessments.
Coordinate with Design, Materials, and Quality teams to align processes with aviation industry standards.
Support supplier onboarding and capability development for future production phases.
Establish process flows and data structures within ERP/MES systems to support qualified and production‑ready processes.
Maintain a clean, safe, and organized AM working environment.
Work effectively in an international, cross‑functional engineering environment.
Participate in training, conferences, and technical exchanges as needed.

Benefits

Competitive Base Wages (pay will be based on several variables that include, but not limited to geographic location, work experience, etc.)
Paid Overtime
Regional Bonus (when applicable)
Industry-leading Benefit Plans (Medical, Dental, Vision, Rx)
Paid time off, including vacation, holidays, shutdown
Company Paid Short-Term and Long-Term Disability
401K Plan with company match + additional contribution
Advancement Opportunities
Career Mobility
Education Reimbursement for Continued Learning
Training and Development Programs
Lifestyle Account
Childcare Reimbursement Account
Tuition Assistance & Student Loan Repayment
Elder Care Support
Wellbeing Program
Community Service and Engagement Programs
Product Programs