Senior Research Engineer (DED, Hybrid Manufacturing), ARTC

Responsibilities

• Lead DED application projects covering repair, remanufacturing, cladding, feature addition, near-net-shape fabrication, and hybrid DED-machining workflows.
• Develop, optimize, and evaluate laser powder Directed Energy Deposition (DED) processes for metallic materials used in repair, remanufacturing, cladding, feature addition, and near-net-shape fabrication.
• Independently plan and deliver DED projects, including process route design, experimental planning, resource estimation, execution, and reporting.
• Develop CAD/CAM and toolpath workflows for complex DED applications, including repair volume definition, geometry preparation, fixture considerations, and deposition strategy.
• Operate, program, and troubleshoot CNC-based and/or robot-based laser powder-fed DED systems, including process setup, safe operation, and monitoring.
• Support DED equipment integration and ownership activities, including commissioning, calibration, preventive maintenance, troubleshooting, safety compliance, risk assessment, SOP development, and operator training.
• Collect and analyse experimental, process, and production data to support process improvement, quality assessment, cost estimation, feasibility evaluation, and technical decision-making.
• Prepare technical reports, project deliverables, presentations, and documentation for internal stakeholders and industry partners.
• Work closely with industry partners, suppliers, and research collaborators to deliver project outcomes, support technology translation, and strengthen DED capability development.

Job Requirements

Minimum Requirements

• Bachelor’s degree in Mechanical Engineering, Manufacturing, Materials Science, Welding, Metallurgy, Additive Manufacturing, or a related discipline.
• Minimum 3 years of hands-on experience in metal Directed Energy Deposition, preferably using laser powder DED systems.
• Strong practical experience in DED process development, including parameter optimization, build strategy, troubleshooting, and defect mitigation.
• Demonstrated ability to plan and deliver DED fabrication, repair, or remanufacturing projects, including technical planning, execution, and reporting.
• Experience with CNC-based and/or robot-based DED systems, including machine operation, toolpath execution, process setup, system troubleshooting, and safe operation.
• Experience with CAD/CAM software for DED applications, including geometry preparation, toolpath generation, repair volume definition, and fixture design.
• Practical knowledge of laser-material interaction, powder delivery, shielding gas, thermal effects, and common DED process challenges such as distortion, cracking, and porosity.
• Strong analytical, troubleshooting, problem-solving, documentation, communication, and teamwork skills.

Preferred Qualifications

• Master’s degree in Additive Manufacturing, Materials Science, Mechanical Engineering, Manufacturing, Welding, Metallurgy, Automation, or a related discipline.
• More than 5 years of direct experience in laser powder DED process development for metallic materials.
• Practical experience in AM part qualification or certification, including inspection, testing, documentation, and evidence generation to support process or part acceptance.
• Knowledge of sensor integration, process monitoring, thermal management, and data-driven process optimization for DED applications.
• Good understanding of metallic materials, welding metallurgy, solidification behaviour, and microstructure-property relationships.
• Experience in hybrid DED-machining workflows, including post-deposition machining planning, machining allowance, fixture/interface design, dimensional restoration, and finishing for functional component delivery.
• Experience supporting DED equipment procurement, installation, commissioning, acceptance testing, SOP preparation, risk assessment, or operator training.
• Familiarity with cost modelling, productivity assessment, build time estimation, material utilization, and feasibility analysis for DED applications.

The above eligibility criteria are not exhaustive. A*STAR may include additional selection criteria based on its prevailing recruitment policies. These policies may be amended from time to time without notice. We regret that only shortlisted candidates will be notified.