Advanced Manufacturing Engineer
ABOUT US
Material Hybrid Manufacturing (MATERIAL) is redefi ning how advanced energy systems are made. We specialize in 3D printing of high-performance energy storage systems, combining additive manufacturing, nanomaterials, and electrochemistry to deliver step-change improvements in effi ciency, energy density, and form-factor flexibility.
At STAR Park in San Marcos, Texas, our multidisciplinary research facility integrates chemistry, advanced manufacturing, and battery systems engineering to develop scalable, next-generation energy technologies for defense and commercial applications.
We are seeking a full-time Advanced Manufacturing Engineer to help lead this next stage of growth. to join our growing team full-time and drive the integration of novel printed batteries into real-world systems.
ROLE OVERVIEW
The Advanced Manufacturing Engineer will lead the design, development, and optimization of additive and hybrid manufacturing processes used to fabricate battery components and structural energy devices. This role bridges mechanical design, process development, and systems integration, ensuring that MATERIAL’s novel printers, materials, and workflows achieve production-level performance..
You’ll work across cell design, CAD modeling, integration, and testing, supporting the development of both half- and full-cell prototypes that power the next generation of drones, robotics, and high-performance electronics.
The Advanced Manufacturing Engineer will work closely with cross-functional teams at STAR Park—including Additive Manufacturing, Chemistry, and Battery Integration—to develop process standards, validate new printer technologies, and translate research into consistent, high-quality manufacturing operations. This role will also collaborate directly with the Engineering Team in Miami, FL, supporting the development and commissioning of next-generation Hybrid3D printing systems. The engineer will partner with the AI and Simulation Teams to integrate process monitoring data and implement predictive print-quality models.
By linking material innovation, mechanical design, and production control, this position plays a pivotal role in establishing a closed feedback loop between design, materials, and manufacturing. Ultimately, the Advanced Manufacturing Engineer ensures seamless coordination between research and production teams to accelerate MATERIAL’s path from prototype to scalable deployment.
KEY RESPONSIBILITIES
● Serve as lead operator for MATERIAL’s Beta and commercial Hybrid3D machines, responsible for daily setup, calibration, print execution, and maintenance.
● Troubleshoot and resolve issues related to fi rmware, G-code, printhead motion, extrusion, and environmental controls.
● Develop, document, and continuously improve machine operation protocols and quality control standards.
● Interface with hardware and software engineers to implement fi rmware updates, parameter tuning, and motion system calibration.
● Maintain uptime, yield, and repeatability metrics across all production and R&D print runs.
● Refine and validate print recipes for hybrid conductive, structural, and active materials.
● Coordinate with the Chemistry and Nanomaterials Teams to qualify inks, slurries, and composites for use on Hybrid3D platforms.
● Lead parameter optimization (layer height, print speed, temperature, flow rate, toolpath) to improve throughput and part performance.
● Collaborate with the AI/Simulation Team to integrate process monitoring data into predictive control algorithms.
● Use CAD/CAM tools (SolidWorks, Fusion 360, nTop) to modify print geometries, create fi xtures, and support prototype development.
● Work with the Battery Integration Team to ensure printed parts align with electrical, thermal, and mechanical system requirements.
● Contribute to the scale-up of additive workflows from prototype to pilot production for AFWERX and dual-use programs.
REQUIREMENTS
● Bachelor’s or Master’s degree in Additive Manufacturing Engineering, Mechanical Engineering, Industrial Engineering, or another engineering discipline with relevant experience in advanced manufacturing or energy storage technologies.
● Hands-on experience operating and troubleshooting 3D printers, CNC machines, or motion-controlled fabrication systems.
● Strong familiarity with 3D printer firmware (e.g., Marlin, Klipper, Duet, RepRap) and G-code programming.
● Ability to diagnose, debug, and repair firmware, motion, or control system errors in real time.
● Proficiency with CAD/CAM design tools and solid understanding of process–structure–property relationships for polymer and composite systems.
● Excellent technical communication, documentation, and problem-solving skills.
PREFERRED QUALIFICATIONS
● Advanced experience in firmware modification, printer control scripting, or CNC machine programming.
● Knowledge of process automation, robotics, or embedded systems for real-time print monitoring.
● Familiarity with DoD/AFWERX or SBIR/STTR-funded R&D environments.
● Experience with multi-material or conductive 3D printing.
● Exposure to finite element or thermal modeling tools (COMSOL, ANSYS).
● Programming experience with Python, MATLAB, or C++ for data analysis or process automation.
BENEFITS
● Competitive salary and benefits package.
● Equity participation opportunity.
● Health and dental insurance options.
● Conference and professional development support.
● Career growth within a multidisciplinary, fast-scaling deep-tech company.
JOIN US
Join MATERIAL and help pioneer the future of advanced manufacturing. As an Advanced Manufacturing Engineer, you’ll take ownership of the Hybrid3D print systems that produce our next-generation batteries — integrating mechanical precision, materials science, and software control to scale the future of hybrid energy manufacturing.
Material Hybrid Manufacturing is an equal opportunity employer. Reasonable accommodations may be made to enable individuals with disabilities to perform essential job functions.
