The R&D Engineer is responsible for developing, optimizing and managing the process involved in the production and handling of metal powders, including but not limited to titanium powder.  This role involves working with cross-functional teams to conduct R&D, ensure the efficient and high-quality manufacturing of metal powder, addressing production challenges, and implementing novel initiatives to enhance productivity and product quality, reduce costs and maintain compliance with industry standards.

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• Develops processes for the manufacturing of metal powders using gas atomization, with a focus on titanium powder.

• Uses DOE for optimizing process parameters for manufacturing metal powder.

• Develops and implements novel methods to process various alloys in Continuum’s greyhound (Foundry) atomizer.

• Develops and scales interstitials (O, N, H, C) mitigation methods and processes for reactive metal powders.

• Develops processes to manufacture and handle reactive powder metals, such as titanium, and establishes quality control procedures for these.

• Uses laboratory analytical instruments to support DOE in timely fashion.

• Collaborates with quality assurance teams to address and resolve quality issues.

• Participates in root cause analysis and corrective action activities to address production related issues.

• Works closely with design, engineering and production teams to ensure seamless integration of manufacturing processes.

• Communicates technical information and findings in cross-functional teams and management.

• Provides training and support to production staff on reactive powder manufacturing processes.

• Stays current with the latest developments in titanium powder metallurgy and processing techniques.

• Collaborates with academic and industry partners on innovative projects and initiatives

• Manages projects related to the development and implementation of novel powder manufacturing processes.

• Coordinates with cross-functional teams to ensure project objectives are met on time and within budget.

• Prepares technical reports, documentation, and presentations for stakeholders.

• Bachelor’s degree in Materials Science, Metallurgical Engineering, Mechanical Engineering or a related field. Master’s Degree preferred.

• 3 - 5 years’ experience in manufacturing engineering, materials science or related field, with a focus on R&D of metal powders.

• Ideally, we’d like to hire someone with experience in the optimization of titanium atomization or similar processes, titanium powder movement between processes, titanium blending/sieving processes, pucking (compressing/ consolidating) of Titanium, and packaging powder process optimization to make sure it meets customer requirements.

• Hands on with common powder metal analytical instruments such as PSD, Flow, XRF, Gas analysis, Electron Microscopy etc.

• Strong understanding of powder metallurgy, properties and manufacturing processes.

• Knowledge of powder consolidation techniques including, but not limited to LPBF, DED, surface coating/cladding, HIP, Powder forging.

• Experience in aerospace, automotive, medical devices or other relevant industries is a plus.

• Relevant certifications, such as Professional Engineer (PE), Six Sigma or similar are desirable.

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• Self-starter, self-motivated

• Aptitude to learn and adapt new technologies

• Excellent problem-solving and analytical skills.

• Collaborator - Supportive of a cross-functional, non-siloed work environment

• Works well under pressure and has a demonstrated ability to meet deadlines.

• Ability to manage multiple projects and prioritize tasks effectively.

• Strong verbal and written communication skills

• The position involves work in a manufacturing facility (loud noises, moving mechanical parts and exposure to metal powders), Laboratory and office environment.

• Strict adherence to safety protocols is required to minimize risks associated with handling hazardous materials.

• The role requires wearing appropriate personal protective equipment (PPE), including steel-toe shoes, protective eyewear, earplugs and respiratory equipment (when working with metal powders).

• Must be able to lift up to 20 lbs.