Role Overview
The Ceramic Additive Process Engineer is responsible for developing, optimizing, and scaling ceramic additive manufacturing processes for advanced applications, including investment casting molds, cores, and high-temperature components. This role focuses on binder jet and related technologies, driving process stability, material performance, and production throughput in a digitally integrated manufacturing environment.
What You'll Do...
- Develop and optimize ceramic additive manufacturing processes, with emphasis on:
- Binder jet printing of molds and cores
- Slurry-based and photopolymer ceramic systems (SLA/DLP where applicable)
- Define and control critical process parameters, including:
- Binder saturation and droplet behavior
- Powder characteristics (PSD, flowability, packing density)
- Layer thickness, recoating, and drying conditions
- Lead development of binder systems and chemistries, including:
- High-temperature capable binders (>2800°F environments)
- Debind and burnout behavior
- Compatibility with superalloy casting processes
- Optimize print quality and resolution, addressing:
- Surface finish
- Dimensional accuracy
- Feature fidelity and defect reduction (streaking, delamination, warping)
- Develop and refine post-processing workflows, including:
- Drying and curing
- Debinding cycles (thermal and/or catalytic)
- Sintering or infiltration strategies (if applicable)
- Collaborate with casting and materials teams to ensure:
- Mold integrity during preheat and pour
- Thermal shock resistance
- Minimal interaction with molten alloys (e.g., Ni-based superalloys)
- Support design-for-additive (DfAM) guidelines for ceramic molds and cores:
- Wall thickness limits
- Drainage/venting strategies
- Structural reinforcement
- Implement in-process monitoring and control systems, including:
- Printhead performance (piezo behavior, meniscus control)