--- title: 'Advanced Engineer, Additive Process at Hyliion' canonical: 'https://feeny.ai/job/advanced-engineer-additive-process-hyliion-austin-4ww2vj4w9n7k' type: 'job' last_seen: '2026-10-13' --- # Advanced Engineer, Additive Process at Hyliion - **Company:** Hyliion - **Location:** Austin, TX - **Posted:** 2026-09-30 - **Last confirmed live:** 2026-10-13 - **Apply:** https://job-boards.greenhouse.io/hyliion/jobs/6212003004 ## Job description Hyliion is committed to creating innovative solutions that enable clean, flexible and affordable electricity production. The Company’s primary focus is to develop distributed power generators that can operate on various fuel sources to future-proof against an ever-changing energy economy. This is an onsite role only. Job Purpose and Overview Step into the world of metal additive manufacturing for the KARNO generator, where advanced laser powder-bed fusion meets real engineering challenge. Engineers in this group work across machine behavior, process optimization, material performance, data analytics, and hardware development to ensure high-quality, repeatable production using metal laser powder-bed fusion systems. If you’re the kind of engineer who enjoys digging into machine behavior, fine-tuning laser strategies, studying how materials evolve layer by layer, and pushing metal AM systems to run cleaner, faster, and more consistently, this team is built for you. The work is hands-on, data-driven, and central to scaling a first-of-its-kind distributed power technology. In this role, you’ll move across the entire additive manufacturing ecosystem. You’ll investigate how machine settings influence melt pools, porosity, and microstructure, and you’ll design controlled experiments to refine parameters and boost repeatability. A big part of the job involves troubleshooting machine quirks, interpreting sensor data, and making sense of real-time process feedback. You’ll also be working closely with design, materials, and hardware teams to bring complex AM components from early prototypes into reliable production. Along the way, you’ll help build the systems, standards, and workflows that turn metal AM into a high-trust, high-reliability manufacturing process for power-generation hardware. Duties and Responsibilities: Parameter Development Focus - Identify and optimize critical-to-function (CTF) parameters that drive mechanical performance, density, porosity, microstructure, and repeatability. - Design and execute experiments (DOE) to map the process window, understand sensitivities, and reduce variation. - Build and maintain parameter sets for new alloys, new hardware, and new machine configurations. - Work with sensor data, log files, and monitoring systems to correlate in-process signatures with part quality. - Develop statistical models, SPC controls, and trend analysis tools to ensure stable production behavior. Machine Development Focus - Improve AM machine capability through hardware tuning, sensor integration, calibration routines, and control-system optimization. - Lead machine troubleshooting, repair activities, and upgrades to improve uptime, repeatability, and print speeds. - Conduct machine characterization using advanced tools and metrology equipment to map laser optics, powder behavior, thermal gradients, and recoater performance. - Support machine-level IQ/OQ/MQ qualification and ongoing PM/maintenance strategies. - Collaborate with equipment vendors and internal engineering teams on new machine features, experimental setups, and pilot systems. Drive automation, digital manufacturing, and data-acquisition improvements for machine performance monitoring. ## Qualifications Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions. Education, Experience and Certifications Required - Bachelor’s degree in mechanical, materials science, aerospace, or related engineering discipline. - Requires a minimum of 5 years of engineering experience after earning a bachelor’s degree; relevant graduate project work can be applied toward requirements. - Direct, hands-on experience with laser powder bed fusion (LPBF) additive manufacturing REQUIRED. - Background in fabrication, prototyping, testing, or process development within an engineering environment. - Ability to interpret engineering drawings, apply GD&T, and understand material properties data. - Strong analytical and root-cause problem-solving skills. - Comfortable working hands-on with machines, tools, test equipment, and mechanical assemblies. ## Skills and Abilities Preferred - Build prep/simulation software like ANSYS Additive Suite, 3DXpert, or Dyndrite. - Experience developing AM parameters, designing DOEs, or using statistical analysis tools (SPC, JMP, Minitab, Python, MATLAB). - Experience troubleshooting AM machines, calibrating optics, repairing systems, or working with machine sensors and controls. - Knowledge of DFAM principles, heat-treat processes, and additive-appropriate material behaviors (e.g., nickel alloys, titanium). - Familiarity with CAD tools (NX, SolidWorks, or similar) and simulation/analysis workflows. - Experience with IQ/OQ/MQ qualification approaches. - Strong communication skills and ability to present findings to cross-functional teams. - Experience in a fast-paced R&D or startup hardware environment. ## Why This Role Matters These engineers sit at the core of enabling scalable, high-performance additive manufacturing for the KARNO generator platform. Your work directly influences machine capability, part quality, manufacturability, and the timeline for scaling production of a first-of-its-kind power-generation technology. ## Role Classification and Working Conditions This is a salaried, exempt-level position. This position typically works in an office environment; and given the nature of our business is also exposed to operations/warehouses/production environments. Physical/Other Requirements - Ability to lift and/or move up to 50 pounds. - Ability to travel domestically, as needed, by plane, automobile, etc. approximately 30% of the time, We are not accepting candidates who require sponsorship for this role at this time. Benefits: - Medical Plans, with PPO or HDHP options - Dental Plans, with buy-up option - Vision Plan - Life Insurance and Accidental Death & Dismemberment Plans, with buy-up options - Short Term Disability, paid for by the company - Long Term Disability, paid for by the company - Flexible Spending Accounts (FSA) - Health Savings Account (HSA) - 401k/Roth 401k - Voluntary Accident Plans - Voluntary Critical Illness Plans - Hospital Indemnity Plan Hyliion is proud to be an equal opportunity/affirmative action employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, gender, gender identity or expression, sexual orientation, national origin, genetics, age, disability, veteran status.  If a reasonable accommodation is needed to participate in the job application or interview process, to perform essential job functions, and/or to otherwise participate in the employment selection process, please direct your inquires to Hyliion’s human resources department at HR@hyliion.com. ## About Hyliion ## Company Overview - **One-liner**: Hyliion develops sustainable, fuel-agnostic linear generator technology for clean, flexible, and affordable electricity production across stationary and mobile applications. - **Entity Type**: Public (NYSE American: HYLN) - **Headquarters**: Cedar Park, Texas, United States (operational presence also in Austin, TX and Cincinnati, OH) - **Founded**: 2015 - **Founders**: Thomas Healy (Founder and CEO) ## Core Business - **Primary industry**: Electric Power Generation / Distributed Energy - **Target customers**: Commercial and industrial facilities, waste management operations, and other entities needing locally deployable prime power or energy arbitrage solutions. - **Mission or purpose**: “Create innovative solutions that enable clean, flexible and affordable electricity production” — with a vision of engineering the electrified future. ## Products & Services - **KARNO™ Power Module**: A fuel-agnostic linear generator enabled by additive manufacturing. Designed to run on various fuel sources (natural gas, hydrogen, biogas, etc.) for stationary power generation. Targets commercial and waste management industries. - **Hypertruck ERX™**: (Earlier product) Hybrid electric powertrain solution for Class 8 commercial trucks; prototype completed and production launched for first KARNO additive components in 2024. ## Market Standing - **Valuation/Market Cap**: Approximately USD 430.5 million (as of 2026 data from LinkedIn) - **Key Metric**: Annual revenue of USD 3.5 million (public company; revenue reported on LinkedIn) - **Notable Investors/Partners**: Total funding of USD 260.2 million, including a USD 233M corporate round in 2020. Early investors include a Series A round (USD 21M, 2017). Acquired Gentherm’s battery division (2018) and the KARNO generator technology (2022). Key executive hires from GE Additive, Cummins, Daimler, and others. - **Growth Signals**: 100 employees (+4.7% YoY); 14 open job postings; successful 100‑day operation of KARNO Power Module on a customer asset (Oct 2025); successful emissions testing milestone (Oct 2025); expanding from transportation to broader stationary power markets. ## Competitive Advantages - **Fuel‑agnostic architecture**: Operates on multiple fuel sources (including hydrogen and biogas), insulating customers from fuel‑price volatility and regulatory shifts. - **Additive manufacturing enabled**: Proprietary linear generator design reduces moving parts and maintenance, while enabling rapid prototyping and customisation. - **Proven reliability**: Demonstrated 100 days of continuous operation on a customer asset. - **Established IP portfolio**: Built through organic development and strategic acquisitions (Gentherm battery division, KARNO generator). ## Strategic Focus - **Transition from transportation to stationary power**: Hyliion’s core focus has shifted from hybrid truck powertrains to distributed linear generators for commercial and waste management customers. - **Scalable production**: Launching additive component production and expanding manufacturing capabilities in Austin and Cincinnati. - **Future‑proofing energy**: Targeting mobile applications (vehicles, marine) beyond stationary power, while maintaining a fuel‑agnostic approach to adapt to evolving energy economies. ## Why Work Here - **Culture**: Values-driven environment emphasizing “Act with Integrity”, “Excellence in All We Do”, “Succeed as One Team”, and “Change the World”. Dog-friendly offices, healthy lunch/snacks provided. - **Benefits**: Generous PTO, comprehensive medical/dental/vision insurance, 401K plan, and two weeks paid parental leave. - **Engineering focus**: 54% of workforce in technical roles; team members drawn from companies like GE Additive, Cummins, Tesla, and Ford. - **Locations**: Primary office in Austin, TX; R&D and manufacturing in Cincinnati, OH; some roles in both. - **Remote/hybrid policy**: Not explicitly stated (likely office-based for engineering and manufacturing roles, though some flexibility may exist). - **Job openings**: 14 active roles across Engineering, Commercial, Operations, and PMO (as of early 2026). ## Sources 1. [hyliion.com](https://www.hyliion.com/) – Company overview, mission, products, and newsroom. 2. [hyliion.com/about-us](https://www.hyliion.com/about-us/) – History timeline, identity, and team values. 3. [hyliion.com/careers](https://www.hyliion.com/careers/) – Benefits, core values, and culture details. 4. [job-boards.greenhouse.io/hyliion](https://job-boards.greenhouse.io/hyliion) – Current job openings and departmental breakdown. 5. [linkedin.com/company/hyliion](https://www.linkedin.com/company/hyliion) – Employee count, revenue, market cap, funding rounds, and workforce demographics. ## Other roles at Hyliion - [Senior Manufacturing Engineer](https://feeny.ai/job/senior-manufacturing-engineer-hyliion-austin-bzgzwk5fxm7x) — Austin, TX - [Manufacturing Engineer](https://feeny.ai/job/manufacturing-engineer-hyliion-austin-8th91nvvgf7w) — Austin, TX - [Technician, Print Operations](https://feeny.ai/job/technician-print-operations-hyliion-austin-40ejsneakck4) — Austin, TX - [Technical Program Manager](https://feeny.ai/job/technical-program-manager-hyliion-austin-4c5bgs90gcte) — Austin, TX - [Advanced Engineer, Combustion](https://feeny.ai/job/advanced-engineer-combustion-hyliion-cincinnati-k8z30hesgemn) — Cincinnati, OH - [Field Service Engineer](https://feeny.ai/job/field-service-engineer-hyliion-austin-ybka3bjrs2e4) — Austin, TX - [Senior Manager, Additive Fleet](https://feeny.ai/job/senior-manager-additive-fleet-hyliion-austin-ep48z9v6c9j7) — Austin, TX - [Technician, Engine Assembly](https://feeny.ai/job/technician-engine-assembly-hyliion-cincinnati-8jjqj5mknz13) — Cincinnati, OH - [Senior Supplier Quality Engineer](https://feeny.ai/job/senior-supplier-quality-engineer-hyliion-cincinnati-r4ehv00b78yf) — Cincinnati, OH - [Manager, Electrical Engineering](https://feeny.ai/job/manager-electrical-engineering-hyliion-austin-zyhh3sgm8amq) — Austin, TX