Advanced Process Engineer (Metal AM)

The posting, as Boom Supersonic wrote it

Boom is building Superpower, a first-of-its-kind industrial gas turbine for behind-the-grid energy generation, and Symphony, the engine that will return supersonic flight to passengers. Both run on high-temperature nickel superalloys, in parts that are already designed. Our job is making sure those parts exist on schedule - and additive manufacturing, running in parallel with castings, is how we guarantee it. We are standing up the metal AM line right now - machines, parameters, applications, and the quality systems to run it reliably. This role is the process engineer at the center of it.

The LPBF problems nobody else will hand you
At an established AM shop, a process engineer runs existing parameter sets on certified machine platforms. The alloys are qualified, the windows are defined, and the job is yield and cycle time. The interesting decisions were made before you arrived.

This is not that job.

Boom needs to print high gamma prime nickel superalloys - the crack-prone, heat-treat-sensitive alloys that break every standard LPBF approach - on extreme-preheat machines the industry is still figuring out, with build-preparation software that gives us control most shops never touch. The parts are designed and the requirements are set; the process to print them doesn't exist. We need the engineer who will design the DOEs, build the parameter sets from scratch, own the application development for real engine parts, and write the process the team runs in production. The supply chain can't do this for us. That's why this role exists.

What you'll do

• Design and execute DOEs for hard-to-print metal alloys on production LPBF machines - and document what you learn
• Develop process parameters from scratch for extreme-preheat platforms printing crack-prone superalloys
• Own part-specific application development: build orientation, support strategy, distortion compensation, depowdering, heat treat and HIP specification, machining interfaces, and inspection plans
• Automate the work: programmatic DOE generation and build prep to minimize manual work and set up files in a fraction of the normal time
• Write the documentation that carries the process from R&D to production: procedures, work instructions, build records, powder reuse tracking, traceability
• Help scope, procure, install, and commission equipment - then use it and train others on it
• Work shoulder-to-shoulder with technicians and M&P engineers - everyone in this lab builds, documents, and troubleshoots

This job is demanding
The manufacturing process you need won't exist yet - you'll develop it. Many of these alloys are notoriously difficult to print and the machines we're bringing in are at the frontier of what the industry has qualified. The parts you print will run in an engine, which means your process rigor, approach to quality, and documentation discipline have to be absolute. If a result is uncertain, we need to know that more than we need it to look ready.

You probably
[…]
matter - sounds like the role you've been looking for, apply.

What is it REALLY like to work at Boom? Find out here .

Compensation

• P3 Level - Typically 5 - 10 years of experience - Base salary range: $137,000 – $184,000
• P4 Level - Typically 10 - 15 years of experience - Base salary range: $153,000 – $205,000
• P5 Level - Typically 15 + years of experience - Base salary range: $168,000 – $225,000

Actual salaries will vary based on factors including but not limited to location, experience, and performance.

There is no set deadline to apply for this job opportunity. Applications will be accepted on an ongoing basis until the search is no longer actives

Benefits
Along with competitive pay and meaningful equity, Boom offers:

• Medical coverage, with Boom paying 70% of medical premiums
• Fully paid dental and vision premiums for employee-only coverage
• A $100–$300 company HSA match on eligible medical plans
• A 401(k) with a company match
• Generous paid time off and company holidays
• Paid parental leave
• Confidential counseling, coaching, and therapy resources for you and your family
• Company-paid life and disability insurance
• Pet insurance
• A $1,000 contribution to Invest America accounts for Boom babies
• Healthy meals, an on-site gym, and a fully stocked kitchen
• Ongoing wellness events
• Discounts on technology, concerts, and rental cars
• A dedicated real estate team to help you find a home

ITAR Requirement
To conform to U.S. Government aerospace technology export regulations (ITAR and EAR), applicant must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State. Learn more about ITAR here.

Boom is an equal opportunity employer, including for individuals with disabilities and protected veterans. We are building a culture of merit and excellence.

Want to build a faster future? Come join Boom.