Additive Manufacturing Researcher Jobs in Chicago, IL

Mid to Senior Level | Chicago, IL | On-site | Phase3D

Phase3D develops sensor hardware that gives manufacturers real-time visibility into their additive manufacturing processes. Our systems are deployed at leading manufacturers and research institutions. We are seeking a Hardware Systems Engineer to take ownership of hardware products from concept through validated production release.

This is a hands-on, cross-functional position. You will work across electrical, mechanical, firmware, and manufacturing disciplines to deliver reliable industrial products, holding full technical ownership of the products you develop.

We evaluate candidates on their demonstrated ability to design, build, and troubleshoot hardware rather than on academic background alone. Our team includes engineers from electrical, mechanical, and mechatronics backgrounds, united by strong technical range and disciplined problem-solving.

Phase3D empowers the additive manufacturing industry (industrial 3D printing) with trusted inspection technologies that deliver objective, layer-by-layer insights into every build. Its core products, Fringe Research and Fringe Qualification, generate precise heightmaps for each layer, helping customers reduce lead times, increase machine utilization, and improve build quality. Using structured light, a proven inspection method, Phase3D’s solutions measure every layer of the 3D printing process, identify anomalies, and support engineers and technicians in process and product optimization.

Phase3D is a small team accomplishing big things in additive manufacturing, including integration of best-in-class metrology systems into the 3D printing supply chain. We work with tier 1 manufacturers, national laboratories, and federal manufacturing depots.

• Design and develop hardware. Design, prototype, bring up, and debug sensor electronic products, including PCBs, enclosures, cabling, circuits, fixtures, mechatronics and system integrations.
• Lead electrical systems engineering. Diagnose and resolve complex electrical challenges, including ground loops, noise, grounding and shielding strategies, signal integrity, and mixed-signal issues in deployed systems. This is the technical core of the role.
• Work across disciplines. Move between electrical, mechanical, and firmware domains. Design enclosures, mounting, and electro-mechanical integrations in SolidWorks or equivalent CAD, and collaborate closely with software on hardware and firmware integration.
• Drive design transfer to production. Lead validation builds, production readiness reviews, design for manufacturability, and technical documentation, and resolve issues encountered during scale-up.
• Conduct root cause analysis. Investigate field, production, and development issues to identify and permanently resolve their underlying causes.
• Manage suppliers and manufacturing partners. Work directly with suppliers and contract manufacturers on development, sourcing, component qualification, and supply chain risk mitigation.
• Support regulatory compliance. Lead CE, EMC, FCC, and UL readiness activities in collaboration with internal and external partners.
• Own project delivery. Serve as technical owner for assigned projects, managing schedules, mitigating risk, and ensuring on-time delivery.

You have designed and shipped hardware products and can point to systems you have developed, debugged, and delivered to customers.

• Hands-on hardware experience across electrical, mechanical, mechatronics, or embedded disciplines. A degree in an engineering field is preferred; equivalent professional experience, including non-traditional and apprenticeship pathways, is equally valued.
• Demonstrated electrical troubleshooting expertise, including the ability to resolve complex ground loop, noise, and signal-integrity problems in operating systems.
• Proficiency in PCB design and prototyping: schematic capture, prototype bring-up, and hardware debugging using Altium, KiCad, OrCAD, or equivalent tools.
• Working proficiency in SolidWorks or comparable CAD software for enclosure design and electro-mechanical integration.
• Experience across the product lifecycle, taking products from prototype through validation and production release, with a working knowledge of design for manufacturability and design transfer.
• Ability to solve ambiguous technical problems independently and with limited direction.
• Strong written and verbal communication skills.

• Experience in additive manufacturing, industrial instrumentation, sensors, robotics or automation, aerospace, or medical devices
• Embedded systems and hardware/software integration, with proficiency in Python, C/C++, or scripting
• Experience with test and validation tools such as LabVIEW, machine vision, or sensing systems
• Manufacturing expertise, including GD&T, Six Sigma, new product introduction, production line setup, and sheet metal design
• CE, EMC, FCC, or UL certification experience and familiarity with risk methodologies such as FMEA
• Familiarity with Linux-based systems and edge computing devices

• Lead development of next-generation Phase3D hardware and improve the reliability and manufacturability of existing products.
• Drive CE and EMC readiness for commercial product releases and deliver projects on schedule.
• Establish scalable engineering practices that support the company's continued growth.

• Advanced industrial technology deployed at leading manufacturers and research organizations
• High ownership and direct technical impact across the full product lifecycle
• A fast-moving environment in which individual engineers meaningfully shape products
• The opportunity to help build next-generation hardware platforms from the ground up

We encourage you to apply even if you do not meet every qualification listed. Many of our strongest engineers built their expertise by taking on unfamiliar challenges.