Description
Process Lead Engineer for Additive Manufacturing
Job ID : 10344
undefined : Burlington, North Carolina, 27215
undefined : 1st Shift
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Description
What Makes a Honda, is Who makes a Honda
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_
Key Accountabilities
\[AM Process Development & Execution\]
- 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).
\[IHM & Outsourcing Supplier Qualification\]
- 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.
\[Others\]
- 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.
Qualifications, Experience, and Skills
Minimum Educational Qualifications:
Bachelor’s degree in Mechanical Engineering, Materials Engineering, Aerospace Engineering, Manufacturing Engineering, or equivalent experience.
Minimum Experience:
Must‑Have Skills
- 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).
Preferred but not required (Want):
- 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.
Other Job-Specific Skills:
- 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 i