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Job Title: Senior Research Engineer – Laser DED / Metal Additive Manufacturing

Department: ARD/RPT, ARTC

Short Description

Role Summary

Senior Research Engineer – Laser Powder Directed Energy Deposition

The Advanced Remanufacturing and Technology Centre (ARTC) is seeking a Senior Research Engineer to join the Remanufacturing Process Technology (RPT) Group and develop laser powder Directed Energy Deposition (DED) capabilities for advanced manufacturing, repair, remanufacturing, and hybrid DED-machining applications.

The role requires hands-on experience in metallic DED process development, including parameter optimization, toolpath and deposition strategy, process planning, machining considerations, experimental execution, data analysis, and project delivery.

Working with researchers, industry partners, suppliers, and collaborators, the candidate will support process innovation, equipment capability development, and technology translation for laser-based additive manufacturing.

Responsibilities

• Lead DED application projects covering repair, remanufacturing, cladding, feature addition, near-net-shape fabrication, and hybrid DED-machining workflows.
• Develop, optimize, and evaluate laser powder Directed Energy Deposition (DED) processes for metallic materials used in repair, remanufacturing, cladding, feature addition, and near-net-shape fabrication.
• Independently plan and deliver DED projects, including process route design, experimental planning, resource estimation, execution, and reporting.
• Develop CAD/CAM and toolpath workflows for complex DED applications, including repair volume definition, geometry preparation, fixture considerations, and deposition strategy.
• Operate, program, and troubleshoot CNC-based and/or robot-based laser powder-fed DED systems, including process setup, safe operation, and monitoring.
• Support DED equipment integration and ownership activities, including commissioning, calibration, preventive maintenance, troubleshooting, safety compliance, risk assessment, SOP development, and operator training.
• Collect and analyse experimental, process, and production data to support process improvement, quality assessment, cost estimation, feasibility evaluation, and technical decision-making.
• Prepare technical reports, project deliverables, presentations, and documentation for internal stakeholders and industry partners.
• Work closely with industry partners, suppliers, and research collaborators to deliver project outcomes, support technology translation, and strengthen DED capability development.

Long Description

Job Requirements

Minimum Requirements

• Bachelor’s degree in Mechanical Engineering, Manufacturing, Materials Science, Welding, Metallurgy, Additive Manufacturing, or a related discipline.
• Minimum 3 years of hands-on experience in metal Directed Energy Deposition, preferably using laser powder DED systems.
• Strong practical experience in DED process development, including parameter optimization, build strategy, troubleshooting, and defect mitigation.
• Demonstrated ability to plan and deliver DED fabrication, repair, or remanufacturing projects, including technical planning, execution, and reporting.
• Experience with CNC-based and/or robot-based DED systems, including machine operation, toolpath execution, process setup, system troubleshooting, and safe operation.
• Experience with CAD/CAM software for DED applications, including geometry preparation, toolpath generation, repair volume definition, and fixture design.
• Practical knowledge of laser-material interaction, powder delivery, shielding gas, thermal effects, and common DED process challenges such as distortion, cracking, and porosity.
• Strong analytical, troubleshooting, problem-solving, documentation, communication, and teamwork skills.