Practical Work Sample Exercises for Hiring Top Additive Manufacturing Engineers

Additive Manufacturing Engineers are at the forefront of innovation in modern manufacturing, bridging the gap between digital design and physical production. Their expertise in 3D printing technologies, materials science, and process optimization directly impacts a company's ability to create cutting-edge products efficiently and cost-effectively. When hiring for this specialized role, traditional interviews alone often fail to reveal a candidate's true capabilities and problem-solving approach.

Work samples and technical skill evaluations provide a window into how candidates actually perform the core functions of an Additive Manufacturing Engineer. By observing candidates as they tackle realistic challenges, hiring managers can assess not only technical proficiency but also critical thinking, attention to detail, and adaptability—all essential traits for success in this rapidly evolving field.

The exercises outlined below are designed to evaluate candidates across multiple dimensions: technical design skills, materials knowledge, troubleshooting abilities, and cross-functional collaboration. Each exercise simulates real-world scenarios that Additive Manufacturing Engineers encounter regularly, allowing you to make more informed hiring decisions based on demonstrated capabilities rather than self-reported experience.

Implementing these work samples will significantly improve your ability to identify candidates who can truly drive innovation in your additive manufacturing operations. The exercises also provide candidates with a realistic preview of the role, helping ensure alignment between their expectations and the actual job requirements—a key factor in long-term retention and success.

Activity #1: CAD Design Optimization Challenge

• Provide a paragraph or two describing the activity and how it demonstrates a necessary skill for the role.

This exercise evaluates a candidate's technical design skills, understanding of design for additive manufacturing (DFAM) principles, and ability to optimize parts for 3D printing. By asking candidates to redesign an existing component, you'll gain insight into their practical knowledge of how to leverage the unique capabilities of additive manufacturing while addressing its constraints.

Directions for the Company:

• Prepare a simple CAD file of a mechanical part that could benefit from redesign for additive manufacturing (e.g., a bracket, housing, or mechanical component with internal features).
• The part should have obvious opportunities for improvement such as weight reduction, consolidation of multiple components, or complex internal structures that would be difficult to manufacture using traditional methods.
• Provide the candidate with the original CAD file, basic specifications (material requirements, load conditions, etc.), and access to CAD software they're comfortable using.
• Allow 60-90 minutes for this exercise.
• Prepare a rubric that evaluates: design creativity, manufacturability, functional improvements, and adherence to DFAM principles.

Directions for the Candidate:

• Review the provided component and its specifications.
• Redesign the part to optimize it for additive manufacturing while maintaining or improving its functionality.
• Consider opportunities for: weight reduction through lattice structures or topology optimization, part consolidation, improved performance features, and design modifications that eliminate the need for support structures.
• Prepare a brief explanation (5 minutes) of your design choices, highlighting the improvements made and manufacturing considerations.
• Export your design in appropriate file formats for 3D printing (.STL, .STEP, etc.).

Feedback Mechanism:

• After the candidate presents their design, provide specific feedback on one aspect they executed well (e.g., "Your lattice structure design effectively reduced weight while maintaining structural integrity").
• Offer one constructive suggestion for improvement (e.g., "The overhang angle in this section might cause printing issues").
• Give the candidate 15 minutes to revise their design based on the feedback and explain how their changes address the concern.

Activity #2: Material Selection and Process Planning

• Provide a paragraph or two describing the activity and how it demonstrates a necessary skill for the role.

This exercise assesses a candidate's knowledge of 3D printing materials, process parameters, and their ability to develop comprehensive manufacturing plans. It reveals their understanding of how material properties, printing technologies, and post-processing requirements interact to achieve desired outcomes.

Directions for the Company:

• Create a scenario involving a product with specific performance requirements (e.g., a medical device requiring biocompatibility, a heat-resistant automotive component, or a flexible consumer product).
• Provide detailed specifications including: functional requirements, environmental conditions, regulatory considerations, production volume, and budget constraints.
• Prepare reference materials with information about various 3D printing technologies and materials that might be applicable.
• Allow 45-60 minutes for this exercise.

Directions for the Candidate:

• Review the product specifications and requirements.
• Recommend the most appropriate additive manufacturing technology and material(s) for this application.
• Develop a comprehensive process plan that includes:
• Pre-processing requirements (file preparation, support generation)
• Process parameters (layer height, print speed, temperature, etc.)
• Post-processing steps (support removal, heat treatment, surface finishing)
• Quality control measures
• Prepare a 10-minute presentation explaining your recommendations and the rationale behind them.
• Address potential challenges and how you would mitigate them.

Feedback Mechanism:

• Provide positive feedback on one aspect of their plan that demonstrates strong technical knowledge or creative problem-solving.
• Identify one area where their approach could be improved or where they may have overlooked an important consideration.
• Ask the candidate to revise that specific portion of their plan and explain how their new approach addresses the concern.

Activity #3: Troubleshooting Simulation

• Provide a paragraph or two describing the activity and how it demonstrates a necessary skill for the role.

This exercise evaluates a candidate's problem-solving abilities, technical knowledge, and systematic approach to diagnosing and resolving issues in additive manufacturing processes. It reveals how candidates think under pressure and their depth of understanding of 3D printing technologies.

Directions for the Company:

• Prepare documentation for a "failed print" scenario, including:
• Photos of the failed part showing specific defects (e.g., warping, layer separation, stringing)
• The original CAD file and sliced print file
• Machine settings and material information
• Brief production history (e.g., "This part printed successfully last month, but recent attempts have failed")
• Create 2-3 deliberate issues that could cause the observed problems (e.g., incorrect temperature settings, material degradation, mechanical issues with the printer).
• Allow 45 minutes for this exercise.

Directions for the Candidate:

• Review all provided information about the failed print.
• Analyze the defects and identify potential causes.
• Develop a systematic troubleshooting plan to identify the root cause(s).
• Recommend specific solutions to resolve the issues.
• Suggest preventive measures to avoid similar problems in the future.
• Document your analysis and recommendations in a format that could be shared with a production team.

Feedback Mechanism:

• Highlight one aspect of their troubleshooting approach that was particularly effective or insightful.
• Identify one area where their analysis could be more thorough or where they missed a potential cause.
• Ask the candidate to expand on that specific area, demonstrating how they would adjust their approach based on the feedback.

Activity #4: Cross-Functional Project Planning

• Provide a paragraph or two describing the activity and how it demonstrates a necessary skill for the role.

This exercise assesses a candidate's ability to plan complex projects and collaborate effectively with cross-functional teams—a critical skill for Additive Manufacturing Engineers who must work with designers, production staff, and quality assurance personnel. It reveals their communication skills, project management approach, and understanding of the entire product development lifecycle.

Directions for the Company:

• Create a scenario for a new product development project that requires additive manufacturing expertise (e.g., a customizable medical device, a complex aerospace component, or a consumer product with unique features).
• Prepare role descriptions for team members from different departments (design, production, quality, marketing) who will participate in the role play.
• Assign company staff to play these roles during the exercise.
• Provide the candidate with project requirements, timeline constraints, and business objectives.
• Allow 60 minutes for preparation and 30 minutes for the role play.

Directions for the Candidate:

• Review the project requirements and develop a comprehensive project plan for implementing additive manufacturing in this product development process.
• Create a timeline with key milestones, identifying critical dependencies and potential bottlenecks.
• Prepare to lead a cross-functional project kickoff meeting where you will:
• Present your implementation plan
• Clarify roles and responsibilities for team members
• Address technical considerations and limitations
• Establish communication protocols and decision-making processes
• Identify potential risks and mitigation strategies
• During the role play, demonstrate your ability to communicate technical concepts clearly, respond to concerns from different stakeholders, and build consensus around your approach.

Feedback Mechanism:

• Provide positive feedback on one aspect of their project planning or communication that was particularly effective.
• Identify one area where their approach could be improved (e.g., addressing a specific stakeholder concern more effectively, providing more detail on a technical aspect).
• Give the candidate 10 minutes to revise their approach to that specific aspect and demonstrate how they would implement the feedback.

Frequently Asked Questions

How long should we allocate for these work sample exercises?

Each exercise requires approximately 1-2 hours, including preparation, execution, and feedback. We recommend scheduling them as separate sessions rather than attempting to complete multiple exercises in a single day, which could lead to candidate fatigue and less reliable results.

Should we provide candidates with preparation materials before the exercises?

Yes, providing basic information about the exercises 24-48 hours in advance allows candidates to prepare appropriately and reduces anxiety. However, specific details (such as the exact design challenge or troubleshooting scenario) should only be revealed during the actual exercise to ensure you're evaluating real-time problem-solving abilities.

How should we evaluate candidates who have experience with different CAD software than what our company uses?

Focus on evaluating the candidate's design thinking and approach rather than their proficiency with specific software. Consider allowing candidates to use CAD software they're familiar with for the exercise, as the core skills (design for additive manufacturing, optimization techniques) are transferable across platforms. Alternatively, provide a brief tutorial on your company's software before the exercise.

What if we don't have the resources to create realistic 3D printing failure scenarios?

If creating physical examples is challenging, you can use well-documented case studies from online resources or educational materials. Many 3D printing communities and manufacturers provide excellent troubleshooting guides with photos of common issues that can serve as the basis for your exercise.

How do we ensure these exercises don't disadvantage candidates from different backgrounds?

Design exercises that focus on fundamental principles rather than industry-specific knowledge that might favor certain backgrounds. Provide clear context and necessary background information so candidates can demonstrate their problem-solving abilities regardless of their specific industry experience. Also, ensure that feedback is based on objective criteria related to the role requirements.

Should we compensate candidates for completing these work samples?

For extensive work samples that require significant time investment, offering compensation demonstrates respect for candidates' time and expertise. This is particularly important for experienced professionals who may be taking time away from current employment to complete your exercises. Even a modest honorarium signals that you value their contribution to the hiring process.

In today's competitive talent market, finding skilled Additive Manufacturing Engineers requires a thoughtful, comprehensive assessment approach. By implementing these work sample exercises, you'll gain deeper insights into candidates' capabilities than traditional interviews alone can provide. This investment in your hiring process will pay dividends through better hiring decisions, reduced turnover, and a stronger additive manufacturing team.

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