Job Description
Who Are We?
ThinkMetal focuses on advanced materials innovation for manufacturing, with a strong emphasis on metal and alloy systems for additive manufacturing. We operate at the intersection of materials science, hardware, and process engineering, building integrated solutions that translate material capabilities into scalable, production-ready systems.
Our work spans metal and alloy development, feedstock engineering, and manufacturing setup design, enabling high performance, reliable, and repeatable industrial processes. We focus on taking materials from lab scale understanding to real world manufacturing deployment, particularly for metal based applications.
As part of the team, you will work in a highly hands-on environment with direct exposure to end-to-end product and process development, from concept and experimentation to production implementation.
Position Overview-
We are seeking a Materials Engineer with strong understanding of metal behavior, alloy applications, and sintering processes for MFAM process (metal filament-based additive manufacturing). The role focuses on process optimization, densification control, microstructure evaluation, and performance validation of sintered metal components.
Key Responsibilities-
- Evaluate and control powder characteristics, including particle size distribution, morphology, flowability, and packing density, to ensure process consistency.
- Develop and optimize debinding and sintering cycles, including ramp rates, hold temperatures, and cooling profiles, for each material system.
- Optimize furnace operation under controlled atmospheres such as argon, hydrogen, or vacuum, and control oxidation and carbon content.
- Analyse shrinkage behaviour and densification mechanisms, and develop dimensional compensation strategies.
- Optimize processing to achieve target density, microstructural uniformity, and controlled grain growth while minimising porosity.
- Design and execute post-sintering heat treatments to achieve target microstructure and mechanical properties.
- Interpret metallurgical characterisation, including optical microscopy, SEM, density, porosity, and shrinkage measurements.
- Interpret mechanical test data (tensile, hardness, and fatigue where applicable) and correlate results with microstructure and processing parameters.
- Troubleshoot defects such as cracking, distortion, porosity, oxidation, and incomplete densification, and lead failure analysis and root-cause investigations.
- Benchmark printed and sintered parts against wrought, cast, or MIM equivalents and relevant standards.
- Apply DoE, regression analysis, and statistical tools for systematic process optimization.
- Use AI/ML tools (Python/MATLAB) to build predictive models for shrinkage, density, and material properties.
- Convert research literature into practical experimental trials and material improvements.
- Follow safe practices for metal powders, high-temperature equipment, and process gases, especially hydrogen.
- Maintain experiment logs, material datasheets, SOPs, and technical reports.
- Contribute to the materials R&D roadmap, including evaluation of new alloys and material systems.
Skills Set
Required Skills
- Physical Metallurgy & Alloy Development
- Powder Metallurgy & Metal Additive Manufacturing
- Debinding, Sintering & Heat Treatment
- Material Testing & Characterisation
- Metallography & Microstructure Interpretation
- Failure Analysis & Root Cause Analysis
- Process Optimization & DoE
Qualification
- Bachelor's or Master's degree in Metallurgical Engineering, Materials Science, or a related field.
- 4-5 years of experience in metallurgy R&D, powder metallurgy, MIM, metal additive manufacturing, or thermal processing. Hands-on academic project or thesis experience will also be considered.
- Strong fundamentals in phase diagrams, phase transformations, sintering mechanisms, and structure–property relationships.
- Knowledge of common engineering alloys such as stainless steels, tool steels, low-alloy steels, and non-ferrous alloys.
- Familiarity with metallography, mechanical testing, and basic characterisation techniques.
Preferred Skills
- Experience with MEX-AM (metal FFF), MIM, binder jetting, or other sinter-based additive manufacturing processes.
- Experience developing debinding and sintering cycles for powder-based parts.
- Exposure to advanced characterisation such as SEM, EDS, XRD, dilatometry, and TGA/DSC.
- Experience with vacuum furnaces and hydrogen atmosphere processing.
- Knowledge of alloy design tools or thermodynamic software (e.g., Thermo-Calc).
- Knowledge of relevant ASTM, ISO, or MPIF standards.
- Basic Python or data analysis (Excel/NumPy/Pandas) for experimental data handling.
What We Offer
Fast-paced, innovation-driven work environment.
Market-standard compensation with performance-based incentives.
Long-term technical growth opportunities.
Opportunity to collaborate with cross-functional teams across R&D, production, materials, and product development.