Process Engineer (New Grad December 2026)

About the Role

Freeform builds AI-native manufacturing systems that unify software, hardware, and physics to produce industrial-scale parts at the speed of human ideation. As a Process Engineer at Freeform, you will have the unique opportunity to help invent novel processes for the world's most advanced metal 3D printing systems. You will work alongside senior engineers to deep dive into complex, multi-physics phenomena, gaining a fundamental understanding of the system and using those learnings to support the creation of new state-of-the-art processes. You will collaborate with an interdisciplinary team of mechanical, software, and simulations engineers to analyze massive in situ data sets as well as post-print material characteristics, helping rapidly iterate on improving the printing technology with machine learning.

Key Responsibilities

• Support the Process Engineering team in developing a deep understanding of the metal additive process and hardware operation by analyzing massive in situ data sets to gain insight into physical mechanisms of the printing process.
• Assist in the execution of experiments, analyze data, and help develop and optimize processes on a metal additive system.
• Perform post-build metrology measurements and analysis of material properties such as tensile strength, surface roughness, and alloy microstructure.
• Generate and track quality metrics of printed customer parts such as dimensional accuracy, defect distribution, and surface roughness.
• Assist in the development and implementation of tool qualification procedures.
• Collaborate with mechanical, software, and simulations engineers to analyze data and support rapid improvement of printing processes.

Requirements & Tech Stack

• Bachelor's degree in materials science, physics, mechanical engineering, or a similar engineering discipline from an ABET accredited university or college.
• First principles thinker with strong fundamentals in physics.
• Coursework or research experience with experimental design and statistical data analysis.
• Strong data analysis skills and ability to interpret important information from large data sets.
• Experience with Python and/or MATLAB.

Qualifications (Nice to Have)

• Advanced degree (Master's, PhD) in materials science, physics, or a similar engineering discipline.
• Undergraduate research experience in material science, physics, or mechanical engineering.
• Process development experience from cutting-edge industries such as semiconductor, solar, or displays.
• Experience with statistical data analysis software such as R, JMP, or Minitab.
• Experience operating complex equipment.
• Familiarity with metallurgical sample preparation such as cutting, grinding, polishing, acid etching, and optical microscopy.
• Passion for developing new processes from scratch.
• Comfortable working in fast-paced, ambiguous environments and iterating quickly.
• Excellent verbal and written communication skills.
• Demonstrated indicators of excellence and/or achieving success against adversity (e.g., top academic performance, leadership in engineering clubs, first-generation college student, or other examples of resilience and achievement).