Sr. PBF Process Control Engineer
RelativityAbout the role
At Relativity Space, we’re building rockets to serve today’s needs and tomorrow’s breakthroughs. Our Terran R vehicle will deliver customer payloads to orbit, meeting the growing demand for launch capacity. But that’s just the start. Achieving commercial success with Terran R will unlock new opportunities to advance science, exploration, and innovation, pioneering progress that reaches beyond the known.
Joining Relativity means becoming part of something where autonomy, ownership, and impact exist at every level. Here, you're not just executing tasks; you're solving problems that haven’t been solved before, helping develop a rocket, a factory, and a business from the ground up. Whether you’re in propulsion, manufacturing, software, avionics, or a corporate function, you’ll collaborate across teams, shape decisions, and see your work come to life in record time. Relativity is a place where creativity and technical rigor go hand in hand, and your voice will help define the stories we’re writing together. Now is a unique moment in time where it’s early enough to leave your mark on the product, the process, and the culture, but far enough along that Terran R is tangible and picking up momentum. The most meaningful work of your career is waiting. Join us.
About the Team:
The Powder Bed Fusion Additive Manufacturing team is pushing the boundaries of what's possible in rocket propulsion hardware. Responsible for development, process, and production, the team oversees initial concept to final hardware with rigorous quality and precision. From developing print parameters on state-of-the-art 3D printers to enabling fast iteration for partner departments, the team plays a critical role in taking engine designs from concept to hot fire. The team was instrumental in producing Aeon 1 engines for Terran 1 launch and is now pioneering next-generation processes and designs for our Aeon R engines that will power Terran R. With flight hardware production scaling up rapidly, now is the time to join and make a direct impact.About the Role:
The Senior PBF Process Control Engineer owns the core PBF process definition for Relativity’s metal additive production systems. You will drive qualification strategies, parameter management, and process stability frameworks across flight hardware production. You will partner closely with M&P, Quality, PBF Development and Production to define how process changes are evaluated and verified, and ensure our specifications stay ahead of design and vehicle demands.
Key Responsibilities
- Lead authorship and stewardship of controlled PBF process specifications (powder reuse, parameter sets, machine maintenance, post-processing, test requirements)
- Own the Process Change Verification workflow — define qualification strategy, build test plans, execute data review and acceptance criteria for new parameter sets, materials, or equipment
- Develop statistical frameworks for process capability (Cpk, tensile variability, powder lifecycle metrics)
- Lead root cause and corrective action efforts for PBF-related non-conformances
- Guide junior engineers in process documentation, data interpretation, and verification test design
- Represent the PBF organization in cross-functional reviews (e.g., Material Review Board, Design Change Board, Qualification Readiness Reviews)
- Drive risk reduction initiatives — parameter validation across machines, environmental controls, powder degradation tracking, and build stability optimization
- Collaborate with Design and M&P on allowable generation and witness coupon strategy to ensure flight margin confidence
- Partner with Quality and Production to streamline AS9100 compliance and data traceability frameworks
- Support hardware failure analysis and lessons-learned integration into process specifications
- Hardware ownership - creating process plans, work orders, and dispositioning non conformances
- Working with Designers on DFAM input
About You:
- B.S. or M.S. in Mechanical, Materials, Aerospace, or Manufacturing Engineering
- 5 + years of industry experience in metal AM process control (or hardware ownership) or special process ownership in aerospace
- Strong understanding of metal AM qualification and material property verification strategies
- Demonstrated experience with controlled specification management and configuration control tools
- Proven ability to analyze
Apply for this role
Generate a tailored application kit with a matched cover letter, interview prep, and CV highlights — in under 60 seconds.
Apply Now →Generate Application KitFree account required — sign up in 30s