Senior Additive Manufacturing Engineer – Directed Energy Deposition (DED)

Senior Additive Manufacturing Engineer – Directed Energy Deposition (DED) 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. Alongside Nyx, we are developing a reusable high‑thrust engine and in‑orbit refueling technologies, positioning TEC to become one of the world’s leading spaceflight companies. To support this mission, TEC is creating a new senior role to industrialize Directed Energy Deposition (DED) for critical aerospace components. 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 e ... (truncated, view full listing at source)