Additive Manufacturing Senior Materials Engineer

Here at The Exploration Company, we are developing, producing, and operating Nyx, a modular and reusable space orbital vehicle that can eventually be refuelled in orbit and that can carry cargo - and potentially humans in the longer run.

We are looking for a talented Additive Manufacturing Senior Materials Engineer to join our mission and contribute significantly to the development and in-house production of additive manufacturing (AM) technologies for our propulsion products powering all our space vehicles.

Role Overview

The ideal candidate will play a key role in the qualification and development of AM processes, including the definition and characterization of print parameters for new materials on larger, more productive machines. This role also involves supporting the certification of AM components to meet high industry standards, including NASA regulations. You will help implement large-scale Directed Energy Deposition (DED) processes and develop functionally graded or bi-metallic components. This is a versatile position with broad responsibilities in additive manufacturing reporting to TEC's Lead for AM.

Key Responsibilities

• Develop and execute materials development and maturation plans for new processes using established alloys, and for existing processes with new alloys.

• Serve as a Senior Materials Engineer for AM projects, collaborating with cross-functional teams to support the development and production of innovative components and systems.

• Operate AM machines in a development environment as needed.

• Assist in the development of new alloys for AM, including maturation of atomization methods and creation of powder specifications.

• Support the qualification and testing of AM processes to ensure compliance with industry standards and performance requirements.

• Conduct tests to analyze samples and validate process parameters.

• Collaborate on the certification of AM processes and parts, particularly those required to meet NASA and aerospace standards.

• Develop post-process heat treatment procedures and specifications.

• Document results and contribute to technical reports and procedures related to AM process qualification and development.

• Troubleshoot and improve AM processes for enhanced performance and reliability.

• Stay up to date with the latest advancements in AM technologies and materials.

• Work closely with engineering, quality, and certification teams to ensure alignment on standards and deliverables.

Qualifications

• Engineering degree in Mechanical/Aerospace Engineering, Materials Science, or a related field.

• Strong experience with AM processes such as laser powder bed fusion and directed energy deposition.

• Strong knowledge of material properties, behavior, testing, and characterization—especially metals used in aerospace applications.

• Familiarity with additive manufacturing standards, including NASA or aerospace industry standards, is highly desirable.

• Experience working in a manufacturing environment producing and delivering hardware.

• Strong analytical skills and a hands-on approach to problem-solving.

• Excellent communication skills and ability to work collaboratively in both internal and external teams.

• Ability to manage multiple tasks and adapt to a dynamic work environment.

Preferred Skills

• Experience with materials modeling, including microstructure and property prediction.

• Proficiency in CAD and simulation software (e.g., NX Suite, ANSYS).

• Familiarity with process qualification and statistical analysis tools.

• Knowledge of quality control methodologies for AM parts, including non-destructive testing (NDT).

Why you should join us!

What makes us special here at The Exploration Company and why we think you will enjoy working here is:  

• We’re Agile - we make decisions fast whilst keeping our goals and systems in mind 

• We’re Open and Collaborative - we are transparent about risks and obstacles, so that we can cooperate to overcome them  

• We have a lot of Fun - we refuel our energy knowing we are democratising space. It’s a wonderful and rare opportunity, are YOU up for the challenge?  

We'd love to hear from you if you wish to be a part of our journey. Please submit your CV now for immediate consideration and we will be in touch shortly. 
 
The Exploration Company is an equal opportunity employer and values diversity. We do not discriminate based on race, religion, colour, national origin, gender, sexual orientation, age, marital status or disability status. Relocation assistance is provided for those willing to relocate including visa sponsorship where applicable.