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Arcturus is building a novel wire technology stack using carbon nanomaterials to overcome performance limitations of metals at high operating temperatures. The company's technology targets significant performance improvements for electric motors in drones and robotics, heat sinks, and energy grid applications.
As Principal Additive Manufacturing Engineer, you will be an early principal technical hire owning major additive manufacturing process development workstreams across LPBF (Laser Powder Bed Fusion), DED (Directed Energy Deposition), and related metal processing methods. This is a high-ownership individual contributor role reporting to the CEO.
Key responsibilities include:
- Owning AM workstreams for carbon nanomaterial-infused aluminum and copper systems, translating technical goals into repeatable process windows and measurable material performance
- Developing process windows that preserve conductivity, mechanical integrity, and nanomaterial performance through fabrication
- Leading parameter development, build strategy, scan strategy, thermal management, and machine troubleshooting
- Serving as senior technical voice on metal AM process physics, melt pool behavior, lasers, powder handling, and print quality
- Leading design-for-additive-manufacturing decisions including build orientation, support strategy, and geometry tradeoffs
- Diagnosing and resolving print failures (porosity, cracking, distortion, bonding issues, density inconsistency)
- Building process maps connecting machine inputs, feedstock, atmosphere, and thermal history to material outcomes
- Partnering across nanomaterials, process, characterization, and product engineering teams
- Developing qualification plans, build records, and process documentation for scale-up
- Using DOE and data analysis to improve yield, repeatability, and cost
- Mentoring junior engineers and technicians as the AM team grows
- Contributing to patent strategy and technical documentation
Required: BS/MS/PhD in mechanical engineering, materials science, manufacturing engineering, or related field. 5+ years hands-on experience in additive manufacturing, metal processing, powder metallurgy, or laser processing. Strong experience with metal AM processes (LPBF, DED, WAAM, EBAM, cold spray). Deep understanding of melt pool physics, heat transfer, solidification, and process-structure-property relationships. Demonstrated ability to develop, optimize, and troubleshoot manufacturing processes in hardware environments. Ability to lead technical workstreams and mentor others. Strong technical writing skills.
Preferred: Deep LPBF/DED experience, aluminum/copper alloy processing, metal matrix composites or carbon nanomaterial-infused metals, machine-level AM development (lasers, optics, motion systems), AM build preparation tools and workflows, process qualification in aerospace/automotive/energy, startup experience.
