Process Engineer

Process Engineer - Ceramics & Photopolymers

Join to apply for the Process Engineer - Ceramics & Photopolymers role at Fabri
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$/yr - $/yr

Fabri is an early‑stage investment casting startup building a fully integrated digital foundry. Our mission is to deliver precision metal castings with unparalleled speed and cost‑effectiveness. Leveraging an exclusive high‑throughput additive manufacturing process and AI‑driven design software, we can deliver castings in days, saving customers critical time and money. We are well capitalized, backed by top‑tier investors and major customers, and have generated significant commercial excitement in both the aerospace and industrial sectors.

Fabri is located in Boston Metrowest; during this startup phase and for the foreseeable future, all employees will be on‑site and closely involved with building and operating the end‑to‑end process. Fabri is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees. We foster an environment where safety and commitment to quality are central in everything we do.

Fabri produces low‑volume, high‑mix investment castings using advanced additive manufacturing and a tightly integrated process workflow. As a Process Engineer, you will own the development and stabilization of the manufacturing steps that most strongly determine final casting quality: (1) ceramic building processes, and (2) additive pattern production (DLP/SLA photopolymers). You will investigate and reduce defects by understanding underlying mechanisms—wetting dynamics, rheology, optical aberrations, surface bonding mechanisms, materials behaviour, stress state, thermal gradients, drying dynamics, gas evolution, handling/fixturing—then translate those learnings into robust process windows, standard work, and scalable production practices.

A key part of this role is partnering closely with Fabri’s software and automation teams to embed manufacturing knowledge into software—turning process rules, constraints, and measurement data into tools that automate decisions, improve traceability, and continuously improve yield.

• Lead root‑cause analysis and corrective actions for defects across printing, shelling/drying, thermal processing, and downstream casting outcomes, with a focus on how the introduction of additively manufactured patterns influence the traditional casting process.
• Design and execute rigorous experimentation programs (DOE), including statistical analysis, measurement system validation, and clear decision criteria.
• Develop and optimize coating process parameters, slurry chemistry (polymer systems, binder systems, solids loading, rheology), stucco strategy, drying conditions, layer schedules, handling/fixturing.
• Develop and optimize burnout and thermal processing of printed patterns to improve shell integrity and dimensional stability, including printed infill geometries, polymer chemistry, furnace profiles, ramp/soak schedules, venting strategies, orientation, and fixture design.
• Own and improve the photopolymer pattern process: printer parameter development, resin handling, resin chemistry, pattern post‑processing, print reliability, dimensional stability, throughput, and influence on subsequent process steps.
• Define key process metrics and implement process controls (SPC where appropriate), including monitoring plans and alarm thresholds.
• Build characterization and metrology workflows with quality teams to quantify defects and validate improvements (e.g., sectioning, microscopy, dimensional/scan‑based methods), and ensure the right data is collected for feedback and reporting.
• Collaborate with software/automation teams to encode process rules and constraints into production software (e.g., parameter capture, recipe management, traceability, defect tagging, data collection) and to close the loop between process outcomes and automated decision‑making.

• Bachelor’s degree in Materials Science/Engineering, Ceramic Engineering, Chemical Engineering, Mechanical Engineering, or a related field.
• 3+ years of experience in hands‑on process…