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Salary: USD 125,000 - 205,000 / annual
Boom Supersonic is building Superpower, an industrial gas turbine for behind-the-grid energy generation, and Symphony, the engine that will return supersonic flight to passengers. Both engines run on high-temperature nickel superalloys in parts already designed. This role is the process engineer at the center of standing up the metal additive manufacturing (AM) line—machines, parameters, applications, and quality systems.
Unlike established AM shops where process engineers run existing parameter sets on certified platforms, this role develops manufacturing processes from scratch. Boom needs to print high gamma prime nickel superalloys—crack-prone, heat-treat-sensitive alloys that break every standard LPBF (laser powder bed fusion) approach—on extreme-preheat machines the industry is still figuring out. The parts are designed and requirements are set; the process to print them does not exist.
You will design and execute design-of-experiments (DOEs) for hard-to-print metal alloys on production LPBF machines, developing process parameters from scratch for extreme-preheat platforms. You'll own part-specific application development including build orientation, support strategy, distortion compensation, depowdering, heat treat and HIP specification, machining interfaces, and inspection plans. You will automate work through programmatic DOE generation and build preparation to minimize manual effort. You'll write documentation that carries the process from R&D to production: procedures, work instructions, build records, powder reuse tracking, and traceability. You'll help scope, procure, install, and commission equipment, then use it and train others. You'll work shoulder-to-shoulder with technicians and materials & processes 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 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.
Requirements:
- Bachelor's, Master's, or PhD in engineering with focus on materials, manufacturing, or additive manufacturing
- 5+ years of experience in LPBF process and/or applications development on real programs with real customers and consequences (exceptional depth can substitute for years)
- Hands-on LPBF experience: personally loaded powder, set up builds, monitored them, and debugged failure modes—not just prepared files
- Process development ownership: parameters you developed, DOEs you designed, failure modes you diagnosed and closed
- Working knowledge of build-prep software such as Dyndrite, Magics, 3DXpert, EOSPrint, Netfabb, or similar
- Programming experience (Python preferred) and instinct to automate anything done twice
- Documentation and traceability habits that would survive a quality audit
Desirable:
- Experience with high-temperature, crack-prone nickel superalloys (high gamma prime alloys)
- Experience on high-preheat LPBF platforms or with reactive metal alloys
- Materials evaluation experience: metallography, SEM, tensile/fatigue/creep testing, fractography, powder characterization
- Exposure to qualification programs: allowables thinking, MMPDS/CMH-17 concepts, statistical treatment of material data
- Experience carrying a process from R&D into production in a regulated environment (AS9100 or similar)
- Startup or prototype-pace experience—comfort in a lab where the process doesn't exist yet and priorities shift fast
ITAR Requirement: Applicant must be a U.S. citizen, lawful permanent resident, protected individual as defined by 8 U.S.C 1324b(a)(3), or eligible to obtain required authorizations from the U.S. Department of State.
