Senior 3D Printing R&D Engineer

About the role

At Form Labs, we are revolutionizing the way ideas are brought to life through advanced 3D printing technology. Our innovative solutions serve a wide range of industries, including aerospace, healthcare, education, and manufacturing. We are seeking a dedicated Senior 3D Printing R&D Engineer to join our team in Somerville, MA, to lead research and development efforts focused on pushing the boundaries of additive manufacturing. This role offers an exciting opportunity to work on cutting-edge projects, develop new printing techniques, and contribute to the future of 3D printing hardware and software. As part of our R&D team, you will collaborate closely with engineers, scientists, and product teams to solve complex engineering challenges and bring innovative products to market.

Key facts

What you'll do

• Lead the development of new 3D printing methods, including designing innovative printer architectures and control systems to improve performance and capabilities.
• Take ownership of research projects aimed at exploring and integrating emerging technologies into our existing product line.
• Tackle complex, undefined engineering problems related to materials, hardware, and software, applying scientific methods to find effective solutions.
• Conduct experiments, collect data, and analyze results to optimize hardware performance and software algorithms.
• Evaluate current printer performance metrics and identify opportunities for enhancement, including improving resolution, speed, and reliability.
• Collaborate with cross-functional teams to incorporate experimental findings into product updates, including refining algorithms and hardware components.
• Develop prototypes and test fixtures to validate new concepts and ensure robustness of new designs.
• Document research processes, experimental procedures, and results thoroughly to support knowledge sharing and future development.
• Present findings to internal teams and stakeholders, translating complex technical data into clear insights and actionable recommendations.
• Stay up-to-date with advancements in additive manufacturing, materials science, and related engineering fields to inform ongoing research efforts.
• Contribute to the intellectual property portfolio by identifying patent opportunities based on innovative research outcomes.
• Support the scaling of new technologies from laboratory prototypes to production-ready solutions, ensuring manufacturability and quality standards are met.

Requirements

• At least 3 years of relevant experience in research and development within the 3D printing, manufacturing, or related engineering fields.
• Proven ability to independently conduct research, analyze experimental data, and develop innovative solutions.
• Strong background in designing and building test fixtures and experimental setups for hardware and software validation.
• Experience with experimental design, data analysis, and scientific computing tools such as Python or Matlab.
• Familiarity with mechanical design, mechatronics, and CAD modeling to develop hardware prototypes.
• Excellent problem-solving skills with a focus on tackling complex, undefined challenges.
• Strong communication skills, capable of presenting technical findings clearly to diverse audiences.
• Bachelor's, Master's, or PhD degree in Mechanical Engineering, Electrical Engineering, Materials Science, or a related discipline.
• Demonstrated ability to work collaboratively in a team environment and manage multiple projects simultaneously.
• Passion for innovation and a keen interest in advancing additive manufacturing technologies.

Nice to have

• Experience working on consumer product development, especially in a manufacturing context.
• Knowledge of physics-based modeling for complex systems to predict material behavior and hardware performance.
• Prior experience with software development for embedded systems or control algorithms.
• Familiarity with ITAR regulations and working within highly regulated environments.

Skills & tools

• Programming languages: Python, Matlab
• CAD modeling and mechanical design tools
• Experimental design and data analysis techniques
• Knowledge of additive manufacturing hardware and software systems
• Ability to develop and test prototypes and fixtures for experimental purposes

Practical notes

• We offer a comprehensive equity program through RSUs to support your financial growth and long-term commitment.
• Our benefits package includes full healthcare coverage, including Medical, Dental, and Vision plans.
• Employees have access to low-cost 401K options, with financial advisors available for planning.
• We provide a generous parental leave policy of up to 16 weeks to support new parents.
• Our tenure-based sabbatical leave allows up to 6 weeks off after a certain period of employment.
• Flexible time-off policies enable you to manage personal needs and work-life balance effectively.
• On-site parking is available, along with pre-tax commuter benefits to ease daily travel.
• Healthy meals and snacks are provided on-site to promote wellness.
• Opportunities for professional development include attending conferences, workshops, and participating in community events.
• Employees have unlimited access to 3D printing facilities for personal projects and experimentation.
• We are committed to fostering a diverse and inclusive workplace, welcoming applicants from all backgrounds.
• We encourage candidates who meet most of the requirements to apply, as we value potential and enthusiasm alongside experience.
• Join us in shaping the future of additive manufacturing and making a tangible impact on industries worldwide.

Compensation

At Form Labs, we believe in rewarding talent and dedication through shared success. The annual salary for this position ranges from $120,000 to $175,000 USD, depending on experience, skills, and the potential contribution to our innovative projects. We also offer equity compensation via RSUs, aligning your success with the company's growth.