---
title: 'Senior Process Engineer (Advanced R&D) at Freeform'
canonical: 'https://feeny.ai/job/senior-process-engineer-advanced-r-d-freeform-los-angeles-h7fj99vwe4df'
type: 'job'
last_seen: '2026-09-12'
---

# Senior Process Engineer (Advanced R&D) at Freeform

- **Company:** Freeform
- **Location:** Los Angeles, CA
- **Posted:** 2026-04-08
- **Last confirmed live:** 2026-09-12
- **Apply:** https://job-boards.greenhouse.io/freeformfuturecorp/jobs/7692975003

## Job description

## SENIOR PROCESS ENGINEER (ADVANCED R&D)

Freeform builds AI-native manufacturing systems that unify software, hardware, and physics to produce industrial-scale parts at the speed of human ideation. By treating manufacturing as a single integrated system, we unlock a new era of innovation where complex hardware is designed, built, and scaled without limits.

As a Senior Process Engineer at Freeform, you will have the unique opportunity to invent novel processes for the world’s most advanced metal 3D printing systems. You will deep dive into complex, multi-physics phenomena to gain a fundamental understanding of the system and use those learnings to create a new state-of-the-art process. You will work alongside an interdisciplinary team of mechanical, software, and simulations engineers to analyze massive in-situ data sets as well as post-print material characteristics and rapidly iterate on improving the printing technology with machine learning. The ideal candidate will be comfortable working in a fast-paced R&D environment, solving very audacious problems from scratch.

3D printing experience is not required to be successful here - rather we look for smart, motivated, collaborative engineers who love solving hard problems and creating amazing technology!

Responsibilities:

- Develop a deep understanding of the metal additive process and hardware operation by analyzing massive in-situ data sets to gain insight into physical mechanisms of the printing process
- Work independently to design and execute experiments, analyze data, and develop and optimize processes on a metal additive system
- Perform post-build metrology measurements and analysis of material properties such as tensile strength, surface roughness, and alloy microstructure
- Generate and track quality metrics of printed customer parts such as dimensional accuracy, defect distribution, and surface roughness
- Develop and implement tool qualification procedures
- Collaborate with mechanical, software, and simulations engineers to analyze data and rapidly improve printing processes
- Strategize continuous improvement plans to enhance system performance, reliability, and scalability

Basic Qualifications:

- Bachelor’s degree in material science, physics, mechanical engineering, or similar engineering discipline
- 5+ years of process development experience in complex physics-based applications such as semiconductor, solar, or additive manufacturing
- Experience developing Design of Experiments (DOE), statistical data analysis, and process optimization
- Experience gathering and processing large data sets

Nice to Have:

- Master’s or PhD in material science, physics, mechanical engineering
- Process development experience from cutting edge industries such as semiconductor, solar, or displays
- Experience with machine learning or data science
- Experience with statistical data analysis software such as R, JMP, Python, or Minitab
- Experience with statistical process control and tool health monitoring
- Experience operating complex equipment
- Familiarity with metallurgical sample preparation such as cutting, grinding, polishing, acid etching, and optical microscopy
- Familiarity with programming languages such as MATLAB or Python
- Passion for developing new processes from scratch
- Excellent verbal and written communication skills

Location:

- Based in Hawthorne, our vertically integrated facility brings technology development, R&D, and production together under one roof. We operate at the center of LA’s deep tech ecosystem, surrounded by some of the most ambitious hardware innovation happening anywhere in the country.

- Our fast-paced, cross-functional environment is built on close collaboration, and as such, this role requires full-time onsite presence (five days a week), with very limited exceptions.

What We Offer:

- We have an inclusive and diverse culture that values collaboration, learning, and making deliberate data-driven decisions.
- We offer a unique opportunity to be an early and integral member of a rapidly growing company that is scaling a world-changing technology.
- Benefits
- Significant stock option packages
- 100% employer-paid Medical, Dental, and Vision insurance (premium PPO and HMO options)
- Life insurance
- Traditional and Roth 401(k)
- Relocation assistance provided
- Paid vacation, sick leave, and company holidays
- Generous Paid Parental Leave and extended transition back to work for the birthing parent
- Free daily catered lunch and dinner, and fully stocked kitchenette
- Casual dress, flexible work hours, and regular catered team building events
- Compensation
- As a growing company, the salary range is intentionally wide as we determine the most appropriate package for each individual taking into consideration years of experience, educational background, and unique skills and abilities as demonstrated throughout the interview process. Our intent is to offer a salary that is commensurate for the company’s current stage of development and allows the employee to grow and develop within a role.
- In addition to the significant stock option package, the estimated salary range for this role is $140,000-$200,000. The upper end of the range is reserved for individuals who demonstrate exceptional experience, deep domain mastery, and a proven history of high performance and impact.
- Freeform is an Equal Opportunity Employer that values diversity; employment with Freeform is governed on the basis of merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.

## About Freeform

## Company Overview
- **One-liner**: Freeform builds the world’s first AI-native manufacturing system – autonomous factories that use advanced sensing, compute, and machine learning to 3D-print industrial-grade metal parts at unprecedented speed and scale.
- **Entity Type**: Private (Series B, raised $67M in Feb 2026)
- **Headquarters**: Hawthorne, California, USA
- **Founded**: 2019
- **Founders**: Erik Palitsch (CEO), Thomas J. Ronacher (President & Co-Founder)

## Core Business
- **Primary industry/industries**: Industrial Automation, Additive Manufacturing (Metal 3D Printing), Physical AI
- **Target customers**: B2B, primarily serving mission-critical industries: Aerospace & Defense, Aviation, Automotive, Advanced Energy, Consumer Electronics, Robotics, and Motor Sports.
- **Mission or purpose statement**: “To radically change the way things are made” and “unlock advanced manufacturing for every industry” by treating manufacturing as a single, integrated AI-native system.

## Products & Services
For each major offering:
- **AI-Native Manufacturing System**: A fully integrated, software-defined network of autonomous factories. This system uses proprietary compute, sensors, controls, and ML to sense, learn, predict, and control metal formation in real-time. It unifies hardware and software to produce industrial-scale parts from prototype to full production, all under one roof.
- **Physical AI Stack**: The company built its own technology stack (compute, sensors, controls, software) to enable a new method of metal 3D printing that is faster, more predictable, and cost-effective than traditional methods.

## Market Standing
- **Valuation/Market Cap**: Not publicly disclosed
- **Key Metric**: Annual Revenue: $4.5M (LinkedIn estimate); Total Funding: $126M
- **Notable Investors/Partners**: NVIDIA (NVentures), AE Industrial Ventures (AE Ventures), Two Sigma Ventures, Founders Fund, Threshold Ventures, 8VC, Linse Capital, Valor.
- **Growth Signals**:
    - Raised $67M Series B in February 2026 to scale up laser AI manufacturing.
    - Named to Fast Company’s “World’s Most Innovative Companies of 2026.”
    - 48 active job postings as of mid-2026, with year-over-year hiring growth of +81.5%.
    - Headcount growth of 9.4% year-over-year (approximately 50 employees).
    - Key hires from SpaceX, Tesla, Apple, Google, Velo3D.

## Competitive Advantages
- **First-principles technology**: The company built all technology from scratch (compute, sensors, controls, ML stack) because the necessary tech didn't exist. This creates a deep technical moat.
- **AI-native, not AI-applied**: Their system is designed from the ground up to be autonomous, learning, and predictive, unlike traditional manufacturing methods that apply AI as an afterthought.
- **Proven leadership**: Founded and led by ex-SpaceX engineers (Erik Palitsch was Principal Architect of the Starship Vehicle and led the Merlin & Raptor engine programs) and a Chief Scientific Officer with deep experience in additive manufacturing (Tasso Lappas, former CTO at Velo3D).
- **Speed and scale**: Promises the ability to go from prototype to full-scale production faster than any competitor, enabling a "death of slow speeds and unpredictable systems."

## Strategic Focus
- **Scale up operations**: The primary focus of the $67M Series B is to scale the technology and expand production capacity.
- **Industry expansion**: Targeting a wide range of industries including aerospace, defense, automotive, energy, and consumer electronics.
- **Talent acquisition**: Aggressively hiring top-tier cross-disciplinary talent (MechE, Electrical, Software, ML/AI, Process, and Engineering leadership) to build out the team.
- **Product innovation**: Continuing to push the boundaries of speed, quality, and scale in metal additive manufacturing.

## Why Work Here
- **Culture**: Described as a team of "first-principles thinkers" with "low ego" and a "healthy sense of humor." The company emphasizes working on "hard problems" and is driven by a mission to fundamentally change manufacturing.
- **Working policy**: Fully on-site in Los Angeles, CA (Hawthorne). This is a shop-floor and lab-heavy environment, ideal for those who want to be hands-on with hardware.
- **Compensation & Equity**: Offers competitive compensation and pre-IPO shares, meaning all employees are shareholders in the company’s success.
- **Notable Perks & Engineering Culture**: Opportunity to work with some of the most advanced manufacturing technology in the world (lasers, robotics, ML). The environment is described as high-trust, high-impact, and cross-disciplinary. The company encourages applications even if there is no exact role listed, signaling a flexible and growth-oriented culture.
- **Talent density**: The team includes top talent from SpaceX, Apple, Google, Tesla, Velo3D, and other leading tech and manufacturing companies.

## Sources
1. [freeform.co](https://freeform.co/)
2. [Freeform Careers](https://freeform.co/careers)
3. [Freeform Company Page](https://freeform.co/company)
4. [Freeform Greenhouse Job Board](https://job-boards.greenhouse.io/freeformfuturecorp)
5. [LinkedIn - Freeform](https://www.linkedin.com/company/freeformfuture)
6. [TechCrunch - $67M Series B](https://techcrunch.com/2026/02/19/freeform-raises-67m-series-b-to-scale-up-laser-ai-manufacturing/)
7. [TechCrunch - $14M Venture Round](https://techcrunch.com/2024/10/22/ex-spacex-engineers-land-14m-to-scale-new-method-for-3d-printing-metal/)

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