Additive Manufacturing Manager

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Once approved to work on the opportunity, you’ll receive the full brief, including the client name, role details, and commercial terms.

Role Details

Company: US-based hard-tech startup

Location: D.C./Baltimore area

Employment Type: Full-time

Work Arrangement: Hybrid, 2–3 days per week onsite

Salary: $175,000–$225,000

Experience: 5+ years in additive manufacturing; relevant expertise considered

Relocation: Relocation support may be available

Tech stack: Metal L-PBF (Laser Powder Bed Fusion), Large-format multi-laser printers, DfAM, Build preparation (orientation, supports, nesting, laser assignment), Parameter development, Build simulation software, CT scanning, Leak and pressure testing, Heat treatment / stress relief, Depowdering, Stainless steel alloys, Nickel alloys

About the Company

An early-stage technology company developing AI-designed metal heat exchangers for high-performance computing and hyperscale data centres. The company combines proprietary AI design technology with advanced metal 3D printing to develop next-generation thermal management solutions.

About the Role

The company is seeking an Additive Manufacturing Manager to establish and lead its in-house metal 3D printing operations. This is a hands-on role combining technical leadership, Design for Additive Manufacturing (DfAM), production optimisation, and quality control.

Responsibilities

• Establish and manage an in-house metal LPBF lab, including equipment commissioning, operating procedures, and technician supervision.

• Lead DfAM optimisation for large, complex metal components, improving printability and identifying design issues early.

• Manage external manufacturing partners, approve build parameters, and ensure production meets specifications.

• Oversee post-processing and quality testing, including depowdering, heat treatment, CT scanning, and leak testing.

• Reduce print times, production costs, and yield losses while supporting future manufacturing expansion.

Requirements

• Hands-on experience with metal Laser Powder Bed Fusion (LPBF) is essential; polymer-only experience is not suitable.

• Experience with large-format, multi-laser metal printers with build envelopes of 400 mm or larger.

• Practical DfAM expertise and experience optimising complex metal components.

• Knowledge of post-processing, quality assurance, and manufacturing validation.

• Experience commissioning equipment, managing production, or holding external manufacturers to quality standards.

• Bachelor's degree in Mechanical, Materials, Manufacturing Engineering, or a related field.

• Ability to work onsite 2–3 days per week.

Nice to Have

• Experience in aerospace, energy, defence, computing, or other high-consequence manufacturing industries.

• Experience building an additive manufacturing lab or managing a fleet of printers.

• Startup experience and a track record of working independently.

• Experience managing technicians and international manufacturing partners.

Benefits

• $175K–$225K base salary plus competitive equity

• Hybrid work, 2–3 days onsite

• Potential relocation signing bonus

• Opportunity to lead advanced metal 3D printing operations

Interview Process

• Candidate submission and initial review

• Interviews with the engineering team

• CEO interview

• Additional technical assessments, if required

• Offer and hiring