Senior Simulation Engineer

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 systems

Requirements

• Bachelor’s degree in applied mathematics, physics, computer science, mechanical engineering, or a related technical field
• 5+ years of professional experience with a bachelor’s degree, or 2+ years with a master’s degree, or a PhD
• 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 (e.g., GPUs)
• Familiarity with solid mechanics, continuum mechanics, or other physical modeling domains

Preferred Qualifications

• MS or PhD in a related technical field
• Experience with real-time or near-real-time simulations on GPU or parallel computing platforms
• Experience with direct numerical simulation (DNS) models
• Experience with thermo-elastic or thermo-elastoplastic modeling
• Familiarity with computational geometry and meshing techniques
• Experience with data-driven modeling techniques and hybrid physics/data simulation methods
• Familiarity with optimization techniques and control theory
• Experience with 2D and 3D meshing libraries and tools

About the Company

Freeform builds AI-native manufacturing systems that unify software, hardware, and physics to produce industrial-scale parts at the speed of human ideation.