Application Engineer - Metal Additive Manufacturing (PBF & WAAM)

Ganpat University · India

Organization : Ganpat University

Department: National Additive Manufacturing Centre West

Designation: Application Engineer – Metal Additive Manufacturing (PBF & WAAM)

Experience Required: 2–5 years in manufacturing/additive manufacturing/application engineering; relevant hands-on AM experience preferred.

Required Qualification: B.E./B.Tech. in Mechanical, Production, Manufacturing, Metallurgy, Materials or allied engineering discipline.

Technical Knowledge: Knowledge of metal additive manufacturing with hands-on exposure to one or more metal AM technologies, preferably Powder Bed Fusion (PBF) and Wire Arc Additive Manufacturing (WAAM). Knowledge of CAD/CAM, build preparation, slicing/toolpath generation, process parameters, DfAM principles, manufacturing practices, metal materials and AM post-processing is preferred.

Job Description:

1. Operate and monitor Metal PBF and WAAM additive manufacturing systems for research, training, demonstration and industrial application activities.

2. Prepare machines, build platforms, fixtures, tooling, wire/powder/feed systems and other required consumables before jobs.

3. Review CAD models, build orientation, support strategy, slicing/toolpath and process plans for AM jobs.

4. Translate application requirements into suitable PBF/WAAM process plans and manufacturing parameters.

5. Execute machine setup, job loading, parameter selection, process monitoring and safe job completion.

6. Conduct first-level troubleshooting of machine, process, software, material-handling and build-related issues.

7. Maintain machine operating logs, build records, parameter sheets, consumable records and application documentation.

8. Support PBF process development including powder handling, build-platform preparation, layer thickness, laser parameters, scan strategy, support structures, build orientation, powder recovery and other relevant process variables.

9. Support WAAM process development including wire selection, substrate preparation, arc/process parameters, deposition strategy, bead geometry, interpass temperature control, torch/toolpath planning, distortion management and machining allowance planning.

10. Perform post-processing coordination including part removal, cleaning, machining, heat treatment and surface finishing as applicable.

11. Inspect manufactured parts using appropriate dimensional, visual and basic quality checks; coordinate advanced inspection when required.

12. Develop and validate AM process windows and application parameters for different materials and component geometries.

13. Support development of prototype parts, functional components, repair/cladding applications, tooling and other industrial demonstrators.

14. Interact with industry partners, faculty, researchers and trainees to understand requirements and communicate technical solutions.

15. Prepare technical quotations, feasibility assessments, job estimates, process plans and application proposals, including preliminary assessment of build time, material consumption, machine hours, post-processing requirements and estimated manufacturing cost.

16. Conduct machine demonstrations, application trials, technical presentations and hands-on training sessions.

17. Coordinate with machine OEMs, material suppliers and external technical agencies for application development and issue resolution.

18. Follow all laboratory, machine, powder/wire handling, PPE, fire, ventilation and other applicable safety procedures.

19. Support preventive maintenance, calibration, consumable planning and coordination of service activities for PBF/WAAM equipment.

20. Maintain application databases, photographs, build reports, lessons learned and case studies for NAMCW's technology-development activities.

21. Support preparation of technical reports, publications, project deliverables and documentation arising from AM projects.

22. Contribute to continuous improvement of NAMCW's Metal PBF and WAAM application-engineering capability and utilization.

Key Result Areas (KRA):

1. Reliable and safe operation of Metal PBF and WAAM facilities.

2. Timely execution of assigned builds, trials, demonstrations and application jobs.

3. Development and validation of process parameters and application solutions.

4. Effective technical communication with industry, faculty, researchers, trainees and technology partners.

5. High machine and facility utilization with minimum avoidable downtime.

6. Accurate documentation of builds, parameters, materials, inspection results and technical outcomes.

7. Timely first-level troubleshooting and coordination of service/support requirements.

8. Delivery of quality prototypes/components meeting agreed technical requirements.

9. Development of reusable AM application knowledge, case studies and training material.

10. Compliance with safety, quality and NAMCW operating procedures.

Key Performance Indicators (KPI):

1. ≥90% of assigned builds/trials executed within the agreed schedule.

2. ≥95% successful first-pass build/job completion for established processes.

3. ≥90% completeness and on-time submission of machine/build/application documentation.

4. Minimum 4 industry/application trials or technical demonstrations supported per quarter per position, subject to demand.

5. First-level technical issues acknowledged and action initiated within 1 working day.

6. Maintain ≥90% availability/utilization readiness of assigned equipment, excluding planned maintenance and external downtime.