Principal Simulation Engineer

About the role

PRINCIPAL SIMULATION ENGINEER

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 Simulation Engineer at Freeform, you will be responsible for developing physics-based, data-driven models that enable the first production scale, high quality, and fully automated metal 3D printing factory capability. We are looking for someone with deep knowledge in physical simulations and multi-physics phenomena who can develop sophisticated models from scratch for undefined or previously unsolved problem statements. This person needs to be comfortable working in an interdisciplinary environment that iterates quickly and decisively.

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 high-performance numerical solvers for simulating the physics of advanced metal 3D printing systems

- Implement numerical simulation models for real-time or near-real-time performance on HPC or GPU platforms

- Work with software engineers to build and deploy physics-based and data-driven models of the laser powder bed fusion process

- Work with software engineers to integrate low-level solvers into simulation pipelines and interface with hardware systems

- Guide the integration of computational geometry and meshing techniques to support large-scale, physics-driven simulations

- Architect simulation modules for execution on specialized compute hardware including FPGAs and GPUs

- Contribute to the development of model-predictive control strategies alongside control engineers

- Generate and maintain documentation for all algorithms, solvers, and integrated system

Basic Qualifications:

- Bachelor’s degree in applied mathematics, physics, computer science, mechanical engineering, or a related technical field

- 10+ years of professional experience developing custom simulation solvers with a PhD in one of the above fields

- Demonstrated experience writing low-level numerical solvers for physical simulations

- Strong programming skills in C, C++, or CUDA

- Experience developing simulations in a high-performance compute environment (i.e. running on GPUs)

- Academic or professional familiarity with solid mechanics, continuum mechanics, or other physical modeling domains

Nice to Have:

- Experience with real-time or near-real-time simulations on GPU or parallel computing platforms

- Experience with direct numerical simulation (DNS) models

- Familiarity with solid mechanics, continuum mechanics, or other physical modeling domains