Senior Additive Engineer
About Forg3D
Metal manufacturing doesn't fail because it lacks intelligence. It fails because it lacks control.
Forg3D is building the control layer for advanced metal manufacturing, starting with wire-based additive processes. We establish controlled, repeatable process envelopes across critical industrial alloys - steels, aluminium, nickel-based alloys, titanium, and refractory metals.
By enforcing fixed process parameters and controlled execution, we deliver repeatable and auditable manufacturing outcomes across machines, sites, and operators. This control layer provides the foundation to qualify, deploy, and scale advanced metal manufacturing in industries where reliability and traceability matter most.
We're a small but growing team building manufacturing capability for energy, aerospace, defence and space applications.
What We Offer
* Private healthcare from day one
* Work that matters in industries where reliability is critical
* 25 days holiday plus bank holidays
* Monthly team socials
What You'll Do
Own WAAM process development end-to-end:
* Develop and scale various deposition processes for a multitude of standard AM alloys including aluminium, and superalloys such as titanium and nickel-based alloys.
* Scale research activities to commercial processes with respect to current qualification routes, in sectors such as fusion, aerospace, defence, and space.
* Program and integrate robotic systems, developing and adding new sensor technologies, identifying and specifying areas for continuous improvement.
* Design and implement post-processing techniques (rolling, peening, heat treatment) to achieve required microstructures.
* Characterise materials and qualify parts for safety-critical applications.
* Translate customer requirements into manufacturable solutions.
* Build production capability as we scale, identifying business needs.
This isn't a narrow lab role. You'll have real ownership from process parameters through to qualified parts reaching customers.
What We're Looking For
You have:
* Hands-on WAAM or wire-DED experience
* PTA/GMA process expertise
* Robotic system programming skills (KUKA, FANUC, or ABB)
* Materials expertise: knowledge of materials science, metallographic preparation, mechanical testing, microscopy analysis
* Experience with challenging materials (titanium, superalloys, aluminium and high-strength steels)
* Multi-layer build strategy and thermal management
* Workshop skills and comfortable getting your hands dirty
* Ability to drive projects independently in a fast-moving environment
* Ability to manage own workload and prioritise work based upon current project requirements.
Nice to have:
* Post-processing experience (rolling, peening, thermomechanical treatment)
* Phase control in complex alloy systems (duplex steels, precipitation-hardening alloys)
* Working in regulated sectors (aerospace, defence, nuclear)
* Industrial R&D partnerships
Candidates must have the right to work in the UK without requiring sponsorship.