Sr. Manager, Simulation Engineering

Job Purpose

The Sr. Manager of Simulation Engineering leads a high-performing team that defines and executes the enterprise simulation strategy for Laser Powder Bed Fusion (LPBF) metal additive manufacturing at VulcanForms. This role owns the long-term roadmap for digital thread enablement and provides the technical leadership needed to develop, validate, and industrialize high-fidelity simulation models, both physics-based and data-driven. In this role, you will bridge process engineering, materials science, multiphysics modeling, computational engineering, and manufacturing systems integration to enable predictive, scalable, production-grade digital manufacturing.

Key Responsibilities

• Define and execute the long-term roadmap for a simulation-enabled digital thread across design, build preparation, process execution, and post-processing.
• Own the strategic vision for the "Simulation-to-Print" pipeline, ensuring seamless integration of high-fidelity simulation solvers into production while balancing short-term needs with long-term strategic objectives.
• Develop KPIs for simulation accuracy, cycle time reduction, yield improvement, and qualification acceleration.
• Provide hands on technical direction in multiphysics modeling including transient heat transfer, thermo-mechanical stress and distortion, powder spreading and recoating, melt pool dynamics, and solidification
• Improve simulation runtime to production-feasible levels, developing scalable workflows for batch part processing, enabling automated support generation and compensation strategies, and implementing distortion compensation and predictive shrinkage correction.
• Oversee simulation software architecture and define APIs and data standards for seamless integration across the digital thread.
• Work cross-functionally to identify, scope, and prioritize high-impact simulation opportunities across the organization.
• Build and mentor a multidisciplinary simulation team by establishing best practices and fostering a culture of technical rigor, data-driven decision-making, and rapid iteration.
• Stay current with the latest advancements in additive manufacturing process modeling, simulation methodologies, compensation strategies, and process control.

Qualifications

• 10+ years of experience with commercial FEA solvers (e.g., Ansys, Abaqus, Simufact, Netfabb) and Python-based automation for simulation.
• Experience developing simulation tools for production environments.
• 5+ years in Additive Manufacturing simulation.
• Master's or PhD in Mechanical Engineering, Materials Science, or Computational Physics.
• Proven experience in nonlinear structural analysis, thermal-mechanical coupling, and residual stress prediction.
• Strong understanding of modeling and simulation codes along with methods development in high-performance computing environments.
• Proven ability to build, lead, and energize cross-functional teams on high-impact technical projects.

Preferred Qualifications

• Experience with commercial simulation tools, physics-based modeling, numerical methods, or computational science to guide technical strategy.
• Experience with 3D printing / LPBF OEM systems.
• Understanding of Ti-6Al-4V, IN 718 & 625, and AlSi10Mg material behavior in LPBF.
• Background in aerospace or medical device qualification standards.
• Ability to translate complex computational results into clear business strategies for cross-functional teams.

VulcanForms offers a competitive salary and equity package. Actual compensation is based on factors such as the candidate's skills, qualifications, and experience. In addition, VulcanForms provides comprehensive benefits including medical, dental, vision, and life insurance; generous paid time off; and a 401(k) plan with company match. 

The annual base salary range for this position is $200,000 to $276,000.