Senior Additive Manufacturing Engineer Jobs in Delaware

Ingersoll Rand is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to age, ancestry, color, family or medical care leave, gender identity or expression, genetic information, marital status, medical condition, national origin, physical or mental disability, political affiliation, protected veteran status, race, religion, sex (including pregnancy), sexual orientation, or any other characteristic protected by applicable laws, regulations and ordinances.

Ingersoll Rand is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to age, ancestry, color, family or medical care leave, gender identity or expression, genetic information, marital status, medical condition, national origin, physical or mental disability, political affiliation, protected veteran status, race, religion, sex (including pregnancy), sexual orientation, or any other characteristic protected by applicable laws, regulations and ordinances.

Job Title: Design for Manufacturing Engineer
Location: Frederica, DE
Job Overview: The Design for Manufacturing Engineer supports the assembly, integration, testing, and pre-ship performance evaluation of operational EVA and IVA spacesuit systems used in safety- and mission-critical applications. This role operates under moderate supervision within established engineering processes and procedures while providing meaningful opportunities for independent technical judgment, problem solving, and continuous improvement. The position provides hands‑on exposure to the full product lifecycle in aerospace engineering, including design, fabrication, manufacturing, assembly, integration, verification, testing, and sustainment activities. Working closely with design engineering, manufacturing, quality, test, supply chain, and program teams, this role is well suited for early-career engineers seeking technical breadth, system‑level understanding, and long‑term growth within aerospace engineering and manufacturing operations.

Responsibilities:

• Provide engineering support for EVA/IVA spacesuit manufacturing operations, including Sewing, Heat Seal, Chemical Processing, Bonding, Cementing, Electronics, and Hardgoods production, to maintain workflow and achieve On-Time‑In‑Full (OTIF) delivery objectives.
• Collect, analyze, and document environmental, mechanical, electrical, and functional test data to support product verification, validation, qualification, and acceptance activities.
• Evaluate and disposition nonconforming hardware in compliance with engineering requirements, quality standards, configuration management processes, NASA requirements, and customer specifications.
• Drive improvements in manufacturing efficiency, product quality, and production throughput through process optimization, tooling enhancements, equipment upgrades, environmental controls, and work instruction updates.
• Collaborate with design engineering teams to incorporate Design for Manufacturability (DFM) principles into new product development, product requirements, and future spacesuit hardware designs.
• Lead failure investigations, root cause analyses, and corrective and preventive action (CAPA) initiatives to improve product reliability, manufacturing performance, and operational effectiveness.
• Develop, review, approve, and maintain configuration‑controlled engineering documentation, including work instructions, assembly and test procedures, engineering changes, nonconformance reports, and product records.
• Support refurbishment, maintenance, sustainment, qualification, and production implementation activities for existing and new EVA spacesuit, glove, and Neutral Buoyancy Laboratory (NBL) hardware.
• Lead material replacement, obsolescence mitigation, shelf‑life extension, and risk reduction initiatives by assessing manufacturing impacts and implementing engineering controls to address quality, safety, and production concerns.
• Support capital equipment, tooling, and automation investments while leading continuous improvement initiatives focused on manufacturing processes, production workflows, performance metrics, and long‑term operational capability.

Requirements:

• Must be authorized to work in the U.S. without sponsorship now or in the future.
• Must be able to access shared databases supporting U.S. Government programs (U.S. Citizen or U.S. Permanent Resident).
• Bachelor of Science degree in Mechanical Engineering, Manufacturing Engineering, Aerospace Engineering, Chemical Engineering, Textile Engineering, Materials Engineering, or a closely related technical discipline.
• 0–5 years of relevant engineering experience supporting design, manufacturing, integration, testing, production, or sustainment activities. Internships, co‑op, laboratory, Formula SAE, robotics, or senior design experience may be considered.
• Foundational understanding of mechanical systems, manufacturing processes, product assemblies, engineering testing methods, and systems verification, validation, acceptance testing, instrumentation, data acquisition, and troubleshooting.
• Proficiency in standard engineering software and CAD‑based 3D modeling; ability to read, interpret, and apply engineering drawings, schematics, specifications, bills of material, work instructions, test procedures, and configuration‑controlled documentation. Familiarity with GD&T is preferred.
• Experience supporting fabrication, assembly, integration, laboratory testing, troubleshooting, or production operations with a proactive, solutions‑oriented approach that balances technical, quality, and schedule requirements.
• Strong verbal and written communication skills with the ability to collaborate effectively across engineering, production, supplier, customer, and cross‑functional teams while managing multiple priorities in a schedule‑driven environment.
• Demonstrated ownership, accountability, and commitment to quality and safety, including compliance with laboratory, manufacturing, and test safety requirements.
• Willingness to travel to local worksites, suppliers, customer locations, and test facilities as required.

Preferences:

• Academic or professional experience supporting aerospace, defense, automotive, energy, robotics, or other high‑reliability engineering products and systems.
• Experience supporting hardware through the design, fabrication, assembly, integration, verification, testing, production, and sustainment lifecycle.
• Familiarity with system‑level testing, environmental testing, functional verification, instrumentation, data acquisition, and performance data analysis.
• Exposure to manufacturing processes such as machining, composites, sheet metal fabrication, additive manufacturing, welding, electronics assembly, or mechanical assembly.
• Experience applying root cause analysis, corrective action methodologies, failure investigations, anomaly resolution, nonconformance management, and hardware disposition processes.
• Understanding of requirements‑driven engineering environments, product lifecycle management (PLM), configuration management, and the development or execution of manufacturing, assembly, and test documentation.
• Knowledge of quality management systems, inspection techniques, production controls, and the use of engineering software, data analysis tools, or visualization applications to support troubleshooting and process improvement.
• Demonstrated ability to communicate technical findings and recommendations effectively to diverse audiences, with evidence of technical initiative, sound engineering judgment, and experience in NASA, aerospace, or government contractor environments preferred.

While performing the duties of this job, the employee is occasionally exposed to wet or humid conditions (non‑weather); fumes or airborne particles; toxic or caustic chemicals. The employee is occasionally exposed to work near moving mechanical parts. The employee is occasionally exposed to electricity. The employee may exposed to minor burns and/or cuts. The noise level in the work environment is usually moderate.

What We Offer

At Ingersoll Rand, we embrace a culture of personal ownership — taking responsibility for our company, our communities, and our environment, as well as our individual health and well‑being. Our comprehensive benefits package is designed to empower you with the tools and support necessary to take charge of your health, ensuring that together, we can continue to make life better. Our range of benefits includes health care options like medical and prescription plans, dental and vision coverage, as well as wellness programs. Additionally, we provide life insurance, a robust 401(k) plan, paid time off, and even an employee stock grant, among other offerings. These benefits are our commitment to you, so you can be your best at work and beyond.

Ingersoll Rand Inc. (NYSE:IR), driven by an entrepreneurial spirit and ownership mindset, is dedicated to helping make life better for our employees, customers and communities. Customers lean on us for our technology‑driven excellence in mission‑critical flow creation and industrial solutions across 40+ respected brands where our products and services excel in the most complex and harsh conditions. Our employees develop customers for life through their daily commitment to expertise, productivity and efficiency. For more information, visit www.IRCO.com .

Ingersoll Rand Inc. (NYSE:IR), driven by an entrepreneurial spirit and ownership mindset, is dedicated to helping make life better for our employees, customers and communities. Customers lean on us for our technology‑driven excellence in mission‑critical flow creation and industrial solutions across 40+ respected brands where our products and services excel in the most complex and harsh conditions. Our employees develop customers for life through their daily commitment to expertise, productivity and efficiency. For more information, visit www.IRCO.com.

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Ingersoll Rand is committed to achieving workforce diversity reflective of our communities. We are an equal opportunity employer. All qualified applicants will receive consideration …