About Blackbird Orbit
Blackbird Orbit is rebuilding the industrial backbone of modern defense manufacturing.
We develop advanced metal and ceramic forming technologies that convert traditionally machined or cast components into scalable domestic production.
Our work sits at the intersection of materials science, manufacturing engineering, and national defense. We focus on enabling high-performance components for aerospace, naval, and expeditionary systems while restoring resilient American manufacturing capacity.
Why Blackbird Orbit
You will work on materials and manufacturing technologies that directly affect the future of American defense manufacturing. Our team operates close to the hardware, and the work moves quickly from concept to real parts.
This role offers the opportunity to shape core materials technology inside a growing advanced manufacturing company.
The Role
Blackbird Orbit is seeking a Senior Materials Scientist to lead development and characterization of advanced metal and ceramic materials used in next-generation injection molding and powder-based manufacturing processes.
This role will work across the full materials lifecycle including powder selection, feedstock formulation, processing behavior, sintering, and final material performance. The Senior Materials Scientist will play a central role in translating material science concepts into manufacturable processes and qualified components for defense applications.
You will work closely with manufacturing engineers and leadership to develop materials systems capable of replacing traditionally machined or cast components with scalable net-shape production.
Responsibilities
Lead development of metal and ceramic materials used in powder-based manufacturing processes including metal injection molding and ceramic injection molding.
Design and evaluate feedstock systems including powder characteristics, particle surface chemistry, binder interactions, and solids loading.
Develop and execute experimental plans to evaluate powder behavior, rheology, compounding, molding, debinding, and sintering.
Characterize material properties including density, microstructure, mechanical performance, corrosion resistance, and environmental durability.
Collaborate with process engineers to translate laboratory materials development into stable manufacturing processes.
Investigate sintering behavior, shrinkage control, oxidation mitigation, and microstructural development in advanced alloys.
Support the design and qualification of components intended to replace legacy machined or cast parts in defense applications.
Develop technical documentation and data packages supporting customer qualification and government-funded programs.
Work directly with equipment including molding systems, furnaces, and analytical tools to support materials development.
Required Qualifications
PhD or MS in Materials Science, Metallurgy, or related field.
Strong background in powder metallurgy, sintering science, or injection molding of metals or ceramics.
Experience designing and executing experimental materials programs.
Hands-on experience with materials characterization techniques such as microscopy, density measurement, mechanical testing, or microstructural analysis.
Strong understanding of phase transformations, diffusion processes, and high-temperature materials behavior.
Ability to translate materials science principles into practical manufacturing outcomes.
Comfort working in a fast-moving hardware environment.
Preferred Experience
Experience with metal injection molding, ceramic injection molding, or powder-based additive manufacturing.
Experience working with stainless steels, refractory metals, carbides, or advanced alloys.
Experience developing feedstocks or binders for powder-based processing.
Familiarity with defense or aerospace component qualification.
Experience supporting government-funded R&D programs such as SBIR, ManTech, or OTA-based projects.
What We Value
Ownership of problems from concept through hardware.
Engineers and scientists who prefer working with real equipment over purely theoretical work.
Clear communication of complex technical ideas.
Curiosity, persistence, and a bias toward action.
Interest in rebuilding domestic manufacturing capability.
Export Control Requirements
Due to the nature of our work and applicable export control regulations, applicants must be a U.S. Person as defined by ITAR (U.S. citizen, permanent resident, or protected individual).
Blackbird Orbit is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, disability, or veteran status.