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Design Engineer for Additively Manufactured Pressurized Aluminum Tank for Space Applications
TASKS
Develop a flight-representative design for a pressurized aluminum tank optimized for metal additive manufacturing and suitable for space applications.
The scope includes design, analysis, manufacturability optimization and test planning.
Provide end-to-end engineering support for a space-grade pressure vessel designed for additive manufacturing, including:
* Review and refine system-level requirements, including:
* Operating pressure and proof/burst margins
* Fluid type (e.g. inert gas, propellant, cryogenic if applicable)
* Temperature range
* Mission profile (cycles, duration, environment)
* Interfaces (valves, mounting, feed lines)
* Define applicable safety factors and failure criteria (NASA STD, ECSS, etc.)
* Develop initial tank architectures, including:
* Geometry (cylindrical, spherical ends, domes)
* Wall thickness and reinforcement strategy
* Integrated features (ports, flanges, bosses)
* Characterization of the critical manufacturing parameters for the 3D printing like:
* Deposition rate (mm/s)
* Velocity
* Thermal dissipation
* Trade-off analysis:
* Mass vs strength
* Manufacturability vs performance
* Conventional vs AM-specific geometries
* Optimize design for:
* Selected AM process (e.g. WAAM, DED, LPBF if applicable)
* Build orientation and support minimization
* Residual stress mitigation
* Distortion control
* Define:
* Material (e.g. AlSi10Mg, 6061/5083 variants if feasible)
* Heat treatment strategy
* Surface finishing requirements
* Perform detailed analyses:
* Pressure vessel stress analysis (static and dynamic simulations)
* Fatigue life estimation (if cyclic loading)
* Fracture mechanics assessment
* Thermal gradients and effects (if relevant)
* Conduct:
* Failure Modes and Effects Analysis (FMEA)
* Leak-before-burst assessment
* Identification of critical failure points (ports, weld-equivalents, layer interfaces)
* Define manufacturing approach:
* Recommended AM technology (WAAM / DED xpzdshu / EBAM)
* Build parameters (high-level)
* Identify post-processing steps:
* Heat treatment
* Machining
* Non-destructive inspection (CT, ultrasound, dye penetrant)
* Develop a test program including:
* Proof pressure test
* Burst test
* Leak testing (helium mass spec or equivalent)
* Structural validation
REQUIRED QUALIFICATIONS
* Mechanical and/or Aerospace University degrees
* English language
* Proven experience (3-5 years) in:
* Aerospace or space hardware design
* Pressure vessels or propellant tanks
* Metal additive manufacturing (DfAM)
* Availability to work on-site in Santander (Spain) or Torino (Italy) in a full-time capacity (no hybrid scheme)