Principal Engineer, Materials

Role Overview

We are seeking a Principal Materials Engineer to lead the development, qualification, and optimization of casting materials and processes for aerospace applications. This role will serve as a technical subject matter expert in casting metallurgy, with a focus on nickel-based superalloys, investment casting, and additively manufactured ceramic molds and cores. Working cross-functionally, you will drive casting technologies from early development through production while strengthening our metallurgical capabilities.

What You'll Do

• Lead the development, qualification, and continuous improvement of casting materials, processes, and heat-treatment methods for aerospace components.
• Serve as the principal technical expert in casting metallurgy, including alloy chemistry, solidification, microstructure, material properties, and casting performance.
• Partner with additive manufacturing, design, manufacturing, and quality teams to develop and optimize printed ceramic molds and cores for high-temperature casting.
• Lead metallurgical investigations, root-cause analyses, and corrective actions related to casting defects, material performance, and process variation.
• Establish and oversee metallurgical characterization, testing methods, laboratory capabilities, and acceptance criteria.
• Support casting process qualification, production readiness, first-article inspections, and material review board activities.
• Develop and maintain engineering specifications, process standards, technical documentation, and qualification plans.
• Collaborate with suppliers, research institutions, customers, and external technical partners to advance casting technologies.
• Provide technical leadership and mentorship to engineers, technicians, and laboratory personnel.

You have

Education

• Bachelor's degree in Metallurgy, Materials Science, Materials Engineering, or a related engineering discipline.

Experience

• 12+ years of relevant experience in casting metallurgy, aerospace materials, gas turbines, or a related field. Equivalent combinations of advanced education and experience will be considered.
• Extensive hands-on experience with casting processes, preferably investment casting of nickel-based or cobalt-based superalloys.
• Experience with metallurgical characterization, mechanical testing, casting process qualification, and root-cause investigations.
• Experience working with ceramic mold systems, high-temperature materials, and casting-related inspection methods.

Skills & Competencies

• Deep understanding of alloy chemistry, melting practices, solidification, heat treatment, microstructure, and casting defects.
• Ability to translate complex metallurgical concepts into practical manufacturing processes, engineering requirements, and quality controls.
• Strong analytical, problem-solving, technical documentation, and communication skills.
• Demonstrated ability to lead technical initiatives, influence cross-functional teams, and mentor others.
• Comfortable working in laboratory, foundry, and production environments within a fast-paced, evolving organization.
• The ability to obtain and maintain a U.S. government issued security clearance is required. U.S. citizenship is required, as only U.S. citizens are eligible for a security clearance

Nice to have

• Master's degree or PhD in Metallurgy, Materials Science, Materials Engineering, or a related field.
• Knowledge of ceramic molds, cores, refractory materials, and their interactions with molten metals.
• Experience with single-crystal, directionally solidified, or equiaxed superalloy casting technologies.
• Experience with ceramic additive manufacturing, including binder jetting, stereolithography, or similar technologies.
• Knowledge of vacuum melting, ceramic processing, hot isostatic pressing (HIP), and post-cast heat treatments.
• Experience with casting simulation tools such as MAGMASOFT, ProCAST, or FLOW-3D CAST.
• Familiarity with aerospace materials specifications, supplier qualification, and industry standards.
• Experience with statistical process control, design of experiments, and analytical tools such as Python, MATLAB, Minitab, or JMP.
• Experience leading technical projects, managing external partnerships, or developing advanced manufacturing processes.

Additional information

If this sounds like you, please submit an application with your resume. This could be the opportunity you are looking for to expand your skills, contribute to a winning team, and work with talented people who love what they do and take pride in our mission.

Pay and benefits

Beehive Industries offers a comprehensive benefits package that includes group Medical, Dental, Life, and Short and Long-Term disability coverage from day one. We also offer a generous 401(k) Retirement Savings Plan with a Company match. Every role at Beehive Industries is bonus eligible and will also receive equity in the company.