Process Safety Engineer, Powders

About Us Founded in 2015 to develop the world’s first industrially scalable laser metal additive manufacturing solution, VulcanForms is reshaping how the world manufactures critical products. We build and operate advanced digital infrastructure that enables innovation, accelerates growth, and supports sustainability across aerospace, defense, medical, and other essential industries. Through our vertically integrated capabilities, including scalable additive manufacturing and precision machining, we deliver true end-to-end production at scale by combining cutting-edge technology with a foundation of proven industrial craftsmanship. Our team brings deep expertise in manufacturing, materials science, software, automation, and operations, united by a shared commitment to quality, curiosity, and accountability. We foster an inclusive culture where people take ownership, solve meaningful problems, and continuously learn, because we believe diverse perspectives lead to better outcomes.

Job Purpose As a Process Safety Engineer at VulcanForms, Devens, MA, you will lead the development and continuous improvement of our powder safety program in support of high-volume metal additive manufacturing. This role is responsible for ensuring the safe handling, processing, and storage of reactive metal powders by establishing robust safety standards, evaluating critical safety systems, and partnering across engineering, operations, and facilities to mitigate risk. As the company's subject matter expert on combustible metal powder hazards, you will help build a scalable safety framework that enables operational excellence while supporting the continued growth of our advanced manufacturing capabilities.

Key Responsibilities

• Develop, maintain, and help improve Vulcan Forms' powder safety framework, including procedures, training materials, FMEAs and Dust Hazard Analyses specific to titanium and other reactive metal powders
• Specify, evaluate, and qualify third-party safety equipment (ventilation, filtration, inerting systems, fire suppression, PPE) across our production facilities
• Conduct powder safety audits; identify gaps, track corrective actions to closure
• Coordinate with facility safety personnel to align on site-specific requirements and support operational readiness reviews
• Perform hands-on validation and verification activities
• Interpret and apply NFPA 660 (Standard for Combustible Metals) and related standards to facility design, equipment procurement, and operational procedures
• Maintain awareness of the evolving regulatory and standards landscape; recommend proactive updates to internal policy
• Interact with third-party safety organizations as needed

Qualifications

• Working knowledge of NFPA 660 and the underlying hazard mechanisms of metal dust fires and explosions
• Experience specifying or evaluating powder handling equipment — gloveboxes, powder recovery systems, ventilation, filtration, or inerting systems
• Comfort working in an active production environment and interfacing with operations and facilities teams

Preferred Qualifications

• Experience with metal AM systems (laser PBF, binder jet, or similar)
• Hands-on experience handling reactive or combustible metal powders in a manufacturing or R&D environment (titanium, aluminum, or similar)
• Familiarity with industrial hygiene sampling and exposure assessment for metal dusts
• Background in regulated manufacturing environments (aerospace, medical devices, or consumer electronics)

VulcanForms offers a competitive salary and equity package. Actual compensation is based on factors such as the candidate's skills, qualifications, and experience. In addition, VulcanForms provides comprehensive benefits including medical, dental, vision, and life insurance; generous paid time off; and a 401(k) plan with company match. The annual base salary range for this position is $137,830.00 to $189,510.00.