NPI Engineer (Product Development)

Job Purpose

• The Senior Development Engineer will design and validate manufacturing processes that deliver safe, efficient processes that meet quality, cost, capacity, and customer requirements. This role is within the Medical Device Business Unit and will support the NPI teams in developing manufacturing processes for new metallic implantable products. This role combines materials science, manufacturing process design, and quality-first process validations to deliver robust manufacturing processes for medical devices.

Key Responsibilities

• Materials Science Expertise:Supportanalysis and interpretation ofmetallic materials, particularly Titanium alloys, as theytransformthrough the manufacturingprocess.

• Manufacturing Process Development:Design andexecuteexperiments that help define manufacturing process windows.

• Process Qualification:Author protocols and reportsthat support process validationssuch asOperational and Performance Qualifications (OQ/PQ),whichwillincludeunderstandingprocess control logic,materials test methods,andstatistical sample sizes.

• Process Implementation:Oversee the implementation of manufacturing processes by collaborating with in-house technicians and external suppliers. Coordinate machine setup and process validation while maintaining technical ownership.

• Process Documentation:Write and maintain detailed work instructions, standard operating procedures (SOPs), and process documentation to ensure repeatable and high-quality production.

• NPI Process Design:Engage in the NPI process as required to understand part requirements and contribute to design-for-manufacturability (DFM) decisions. Work closely with design, quality, and production teams to align on cost, capability, and scalability.

• Process Improvement:Identify opportunities forprocess improvements aimed at scrap reduction and cost savings using root cause analysis, lean tools,and data-drivendecision-making.

Qualifications

• Bachelor’s degree in Mechanical, Manufacturing,orMaterials Science(or related field)

• Demonstrated expertise inmaterials science of metals, particularly titanium alloys.

• 5+ years of experience inprocess design and qualification, with a particular focuson3D printing technologies such aslaser metal powder bed fusion.

• Hands-on experience developing and scaling production processes

• Proficiency in process qualification tools and methods (e.g., PFMEA, DOE, IQ/OQ/PQ)

• Strong cross-functional collaboration skills, including working with suppliers, technicians, and internal engineering, quality, and production teams

• Experience creating and maintaining process documentation (e.g., SOPs, work instructions, validation plans)

• Knowledge of Lean Manufacturing, root cause analysis, and continuous improvement methods

Preferred Qualifications

• Familiarity with post-processing techniques, GD&T, and tooling design (hands-on or oversight)

• Background in regulated or quality-controlled environments (e.g., medical device, aerospace) and experience qualifying equipment or automated processes

• Exposure to ERP/MES systems, manufacturing data tools, and safety or ergonomic assessments

VulcanForms offers a competitive salary and equity package. Actual compensation is based on factors such as the candidate's skills, qualifications, and experience. In addition, VulcanForms provides comprehensive benefits including medical, dental, vision, and life insurance; generous paid time off; and a 401(k) plan with company match.

The annual base salary range for this position is $106,500 to $146,000

About Us

Founded in 2015 to develop the world’s first industrially scalable laser metal additive manufacturing solution, VulcanForms is reshaping how the world manufactures critical products. We build and operate advanced digital infrastructure that enables innovation, accelerates growth, and supports sustainability across aerospace, defense, medical, and other essential industries. Through our vertically integrated capabilities, including scalable additive manufacturing and precision machining, we deliver true end-to-end production at scale by combining cutting-edge technology with a foundation of proven industrial craftsmanship. Our team brings deep expertise in manufacturing, materials science, software, automation, and operations, united by a shared commitment to quality, curiosity, and accountability. We foster an inclusive culture where people take ownership, solve meaningful problems, and continuously learn, because we believe diverse perspectives lead to better outcomes.