Senior Additive Manufacturing Engineer (WAAM)

An exciting opportunity has arisen for a Senior Additive Manufacturing Engineer to join a cutting-edge advanced manufacturing team focused on the development and production of high-integrity aerospace and defence components.
This role will play a key part in the development and optimisation of large-scale Wire Arc Additive Manufacturing (WAAM) processes, transforming complex aerospace designs into production-ready components. Working at the forefront of additive manufacturing technology, you will be responsible for process development, robotic integration, path planning, thermal management and quality assurance across the full manufacturing lifecycle.

Key Responsibilities

Develop, validate and optimise WAAM deposition parameters for aerospace-grade materials including Titanium, Inconel and Aluminium.
Generate and optimise multi-axis robotic deposition paths using specialist additive manufacturing software.
Develop thermal management strategies to control distortion, residual stress and microstructural integrity.
Support New Product Introduction (NPI) activities, converting CAD designs into WAAM-optimised near-net-shape components.
Program, configure and maintain integrated WAAM cells, including robotic systems and welding equipment.
Work closely with manufacturing, design and quality teams to ensure efficient and repeatable production processes.
Drive continuous improvement initiatives focused on quality, productivity and process capability.
Ensure compliance with aerospace and defence quality standards, including AS9100 and additive manufacturing regulations.
Conduct root cause investigations and implement corrective actions for process and manufacturing issues.

Required Skills & Experience

Essential

Degree or Master's qualification in Manufacturing Engineering, Mechanical Engineering, Materials Science, Aerospace Engineering or a related discipline.
Minimum 3 years' hands-on experience with Directed Energy Deposition (DED) technologies, specifically Wire Arc Additive Manufacturing (WAAM).
Experience within aerospace, defence, space or other high-integrity manufacturing environments.
Strong understanding of CNC machining, including milling and turning operations up to 5-axis.
Experience with CAM software and manufacturing process development.
Knowledge of robotics, automation and multi-axis manufacturing systems.
Understanding of aerospace metallurgy, weld deposition processes and material behaviour.
Experience using CAD software to create and interpret engineering drawings.
Familiarity with MRP/ERP systems and management of BOMs and manufacturing routings.
Strong problem-solving skills using methodologies such as 8D, FMEA and 5 Whys.

Desirable

Experience with ABB robotic systems and Fronius welding equipment.
HyperMill CAM experience.
Knowledge of Lean Manufacturing, Six Sigma and continuous improvement methodologies.
Experience developing tooling, fixtures and manufacturing strategies for prototype and low-volume production environments.
PhD or research background focused on WAAM, DED or advanced manufacturing technologies.

What's on Offer

Permanent position within a highly advanced manufacturing environment.
Four-day working week offering excellent work-life balance.
Opportunity to work on pioneering aerospace and defence technologies.
Involvement in cutting-edge additive manufacturing and robotic automation projects.
Excellent opportunities for professional development and career progression.

Security Requirements

Due to the nature of the work, candidates must be eligible to obtain and maintain Security Clearance (SC). Applicants will typically need to demonstrate a minimum of five years' continuous UK residency to satisfy clearance requirements