Principal Applications Engineer

COMPANY DESCRIPTION:

Nikon SLM Solutions is a leading provider of metal based additive manufacturing technology, commonly referred to as 3D printers, utilizing selective laser melting and powder bed fusion technology. Our 3D printers are designed to produce parts directly from a variety of metal powders. The customers for our metal based additive manufacturing systems come from various industries such as aerospace, energy, healthcare, and automotive. Headquartered in Lübeck Germany, Nikon SLM Solutions has approximately 600 employees worldwide.

POSITION DESCRIPTION:

The Principal Application Engineer serves as the technical authority for complex metal additive manufacturing (L-PBF) application projects and strategic customer engagements. This role provides expert guidance throughout the entire additive manufacturing process, from design for additive manufacturing (DfAM) through qualification and production, while supporting customers in highly regulated industries such as aerospace, defense, medical, and energy. The Principal Application Engineer partners closely with customers and cross-functional teams to develop manufacturable solutions, optimize processes, resolve technical challenges, and advance best practices across the organization.

CANDIDATE RESPONSIBILITIES:

• Serve as the senior technical lead for customer application projects, including design reviews, benchmarking activities, factory acceptance tests (FAT), and manufacturing feasibility assessments.
• Act as the primary technical interface for strategic customers, translating application requirements into practical and manufacturable L-PBF solutions.
• Provide technical leadership throughout the complete L-PBF manufacturing process, including DfAM, build preparation, parameter selection, machine setup, powder management, post-processing, inspection, qualification, and final part release.
• Evaluate part manufacturability and recommend design improvements that leverage additive manufacturing advantages, including weight reduction, part consolidation, lattice structures, internal channels, topology optimization, and thermal management.
• Support parameter development and process optimization for new materials, geometries, and customer applications.
• Lead investigations into build failures, process deviations, and quality concerns by performing root cause analyses and implementing corrective actions.
• Analyze machine data, build monitoring information, CT scan results, mechanical testing, metallurgical data, and qualification reports to identify process improvements and ensure product quality.
• Develop and maintain application engineering best practices, design guidelines, technical standards, qualification templates, and lessons learned documentation.
• Partner with Materials, Quality, Manufacturing, and Product Development teams to ensure final part performance meets customer and regulatory requirements.
• Evaluate and implement new software, simulation tools, automation technologies, and data analysis methods to improve engineering efficiency and application performance.
• Prepare technical proposals, white papers, customer presentations, manufacturing assessments, and technical reports.
• Mentor Application Engineers, Process Engineers, Designers, Technicians, and Sales teams by providing technical guidance and knowledge sharing.
• Maintain strong customer relationships while representing Nikon SLM Solutions at customer meetings, audits, technical conferences, and industry events.
• Ensure compliance with applicable quality systems, documentation requirements, traceability standards, and industry regulations.

CANDIDATE QUALIFICATIONS:

Required Qualifications

• Master's degree or Ph.D. in Mechanical Engineering, Materials Science, Metallurgy, Manufacturing Engineering, Aerospace Engineering, or a related technical discipline.
• Extensive hands-on experience with Laser Powder Bed Fusion (L-PBF) metal additive manufacturing.
• Demonstrated expertise across the complete additive manufacturing process, including build preparation, parameter development, post-processing, inspection, and qualification.
• Experience supporting customers within regulated industries such as aerospace, defense, medical, energy, or industrial manufacturing.
• Strong understanding of process-structure-property relationships, including melt pool behavior, residual stress, porosity mechanisms, microstructure development, cracking, anisotropy, and heat treatment.
• Experience with common L-PBF materials including titanium alloys, aluminum alloys, nickel superalloys, stainless steels, maraging steels, cobalt chrome, and copper alloys.
• Strong understanding of powder handling, material traceability, contamination control, and feedstock management.
• Experience troubleshooting additive manufacturing processes including laser parameters, recoating, gas flow, preheating, and build monitoring.
• Demonstrated experience leading customer design reviews, qualification planning, and technical risk assessments.
• Strong written and verbal communication skills with the ability to present highly technical information to customers and executive stakeholders.

Preferred Qualifications

• Experience with DfAM and computational design software such as Siemens NX, CATIA, SolidWorks, Autodesk Fusion, or nTop.
• Experience using additive manufacturing software including Materialise Magics, Netfabb, 3DXpert, or AM Studio.
• Familiarity with simulation software such as Amphyon, PanX, Ansys Additive, or Simufact Additive.
• Knowledge of ISO/ASTM additive manufacturing standards, SAE AMS specifications, and qualification methodologies.
• Experience analyzing CT scan data, machine logs, qualification datasets, and non-destructive evaluation (NDE) results.
• Previous experience mentoring technical teams and leading cross-functional engineering initiatives.

OUR COMPREHENSIVE BENEFITS PACKAGE INCLUDES:

• Health coverage including medical, dental, and vision
• 401(k) plan and 4% match
• Holiday Pay and Paid Time Off
• Paid parental leave
• Gym reimbursement
• Tuition reimbursement
• Company-paid disability coverage
• Company-paid life insurance

Nikon SLM Solutions is an Equal Employment Opportunity (EEO) employer. All qualified applicants will receive consideration for employment and will not be discriminated against on the basis of religion, sex, sexual orientation, national origin, age, veteran status, disability status, or genetic information; U.S. citizenship or Green Card is required.