Senior Additive Manufacturing Materials Engineer

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.

In addition to Nyx, we are actively developing Typhoon, the largest full-flow staged combustion engine ever to be built in Europe.

We are looking for a talented Senior Additive Manufacturing Materials Engineer to join our mission and contribute significantly to the development and in-house production of additive manufacturing (AM) technologies for our propulsion products powering all our space vehicles.

ROLE OVERVIEW

The ideal candidate will play a key role in the qualification and development of AM processes, including the definition and characterization of print parameters for new materials on larger, more productive machines. This role also involves supporting the certification of AM components to meet high industry standards, including NASA regulations. You will help implement large-scale Directed Energy Deposition (DED) processes and develop functionally graded or bi-metallic components. This is a versatile position with broad hands-on responsibilities in additive manufacturing reporting to TEC's Lead for AM.

KEY RESPONSIBILITIES

• Develop and execute materials development and maturation plans for new processes using established alloys, and for existing processes with new alloys.

• Serve as a Materials Engineer for AM projects, collaborating with cross-functional teams to support the development and production of innovative components and systems.

• Operate AM machines in a development environment as needed.

• Assist in the development of new alloys for AM, including maturation of atomization methods and creation of powder specifications.

• Support the qualification and testing of AM processes to ensure compliance with industry standards and performance requirements.

• Responsible for onsite materials and powder characterization equipment & laboratory, including selection of equipment, budget for consumables and maintenance, training and standard operating procedures.

• Collaborate on the certification of AM processes and parts, particularly those required to meet NASA and aerospace standards.

• Develop post-process heat treatment procedures and specifications.

• Document results and contribute to technical reports and procedures related to AM process qualification and development.

• Troubleshoot and improve AM processes for enhanced performance and reliability.

• Stay up to date with the latest advancements in AM technologies and materials.

• Act as an onsite quality organization delegate.

QUALIFICATIONS

• Engineering degree in Materials Science , Metallurgy, Welding or a related field.

• Experience with AM processes such as laser powder bed fusion and directed energy deposition.

• Strong knowledge of material properties, behavior, testing, and characterization—especially metals used in aerospace propulsion applications.

• Familiarity with additive manufacturing standards, including NASA or aerospace industry standards, is highly desirable.

• Experience working in an ISO 9001 or similar manufacturing environment producing and delivering hardware.

• Extreme sense of ownership and responsibility for work assigned, striving to complete on-time , exceptional quality, and under budget.

• Strong analytical skills and a hands-on approach to problem-solving.

• Excellent communication skills and ability to work collaboratively in both internal and external teams.

• Ability to manage multiple tasks and adapt to a dynamic work environment.

PREFERRED SKILLS

• Experience with materials modeling, including microstructure and property prediction.

• Proficiency in CAD and simulation software (e.g., NX Suite, ANSYS).

• Familiarity with process qualification and statistical analysis tools.

• Knowledge of quality control methodologies for AM parts, including non-destructive testing (NDT).

Please note that applications are only considered from nationals of one of the following States: Austria, Belgium, Czechia, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Ireland, Italy, Luxembourg, the Netherlands, Norway, Poland, Portugal, Romania, Slovenia, Spain, Sweden, Switzerland, the United Kingdom and Canada, Cyprus, Latvia, Lithuania and Slovakia.

According to the ESA Convention, staff shall be recruited on the basis of their qualifications, taking into account an adequate distribution of posts among nationals of the Member States.

The working languages of the Agency are English and French. A good knowledge of one of these is required. Knowledge of another Member State language would be an asset.

Why you should join us!

What makes us special here at The Exploration Company and why we think you will enjoy working here is:  

• We’re Agile - we make decisions fast whilst keeping our goals and systems in mind 

• We’re Open and Collaborative - we are transparent about risks and obstacles, so that we can cooperate to overcome them  

• We have a lot of Fun - we refuel our energy knowing we are democratising space. It’s a wonderful and rare opportunity, are YOU up for the challenge?  

We'd love to hear from you if you wish to be a part of our journey. Please submit your CV now for immediate consideration and we will be in touch shortly. 

The Exploration Company is an equal opportunity employer and values diversity. We do not discriminate based on race, religion, colour, national origin, gender, sexual orientation, age, marital status or disability status. Relocation assistance is provided for those willing to relocate including visa sponsorship where applicable.