Senior Additive Manufacturing Engineer - Directed Energy Deposition (DED)

Senior Additive Manufacturing Engineer - Directed Energy Deposition (DED)

The Exploration Company

Düsseldorf, Germany

Role Overview

As Senior Additive Manufacturing Engineer – DED, you will be TEC’s technology owner for Directed Energy Deposition. You will lead the creation, qualification, and scaling of DED capabilities for high‑performance aerospace hardware - including complex propulsion components such as nozzles and thrust‑chamber structures.

This is a highly autonomous, technically demanding role with direct impact on TEC’s flight hardware, manufacturing strategy, and future production roadmap.

Key Responsibilities

Technology Development & Industrialization

• Lead the development, maturation, and industrialization of TEC’s DED manufacturing capabilities.
• Define and implement manufacturing workflows across design, deposition, post‑processing, inspection, and certification.
• Establish robust DED process windows for high‑performance alloys, including copper, nickel superalloys, and titanium.
• Guide design teams on DfAM for DED, ensuring manufacturability and performance for complex components like rocket nozzles.

Operational & Program Execution

• Own DED process development from equipment selection and installation through to production readiness.
• Lead part‑qualification campaigns, including test plans, coupons, NDT, acceptance criteria, and documentation.
• Manage budgets, schedules, and risk for DED technology development activities.
• Drive continuous improvement across equipment utilization, uptime, and throughput.

Standards & Quality Compliance

• Ensure all DED processes comply with ESA, NASA, AS/EN9100, and internal TEC quality and safety standards.
• Define process control plans, calibration routines, and traceability workflows for production hardware.

Cross‑Functional Collaboration

• Partner closely with Design Engineering, Materials & Processes, Quality, and external customers to deliver flight‑ready parts.
• Support Make/Buy decisions and work with the propulsion, structures, and systems teams on component qualification.

Supplier & Equipment Management

• Evaluate, onboard, and manage external suppliers including machine OEMs, powder/wire suppliers, heat‑treat vendors, and test labs.
• Ensure DED machines, robotics systems, and tooling are properly maintained, calibrated, and production‑ready.

Documentation & Reporting

• Generate and maintain detailed documentation for processes, test results, deviations, and improvements.
• Provide clear technical reporting to leadership, customers, partners, and certification bodies.

Required Qualifications

• Bachelor’s or Master’s degree in Mechanical Engineering, Materials Science, Aerospace Engineering, or related field.
• 5+ years experience in advanced manufacturing technology development and qualification.
• 3+ years of hands‑on experience with DED processes in an industrial environment.
• Strong foundation in welding metallurgy, heat input control, residual stress management, and mechanical performance.
• Experience applying ESA, NASA, or comparable aerospace standards to manufacturing processes and flight hardware qualification.
• Strong communication, problem‑solving, and cross‑functional collaboration skills.
• Proficiency with data analysis tools to support process control and quality assurance.
• Fluent in English.

Preferred Qualifications

• Experience with robotic toolpath programming for DED systems.
• Metallurgical expertise in copper alloys, nickel‑base superalloys, and their weldability.
• Familiarity with CAM systems, welding simulation tools, and thermal‑mechanical modeling.
• Experience in manufacturing for propulsion systems or other high‑stress aerospace components.