Senior Process/Manufacturing Engineer

Job Summary

In this role, you will lead the research, development, and scale-up of advanced materials manufacturing technologies for next-generation medical devices, with a primary focus on innovative syringe coating platforms and complementary advanced materials research. You will identify, evaluate, and adapt frontier manufacturing technologies from industries such as semiconductor, electronics, aerospace, energy, and precision manufacturing for application in healthcare and medical device development. Working across multidisciplinary teams, you will drive novel process innovation from laboratory proof-of-concept through pilot-scale implementation by developing robust, scalable, and reproducible manufacturing processes. You will apply expertise in advanced materials processing, surface engineering, coatings, polymer and thin-film technologies, process optimization, and analytical characterization to establish the scientific understanding and manufacturing capability required for successful technology translation. In addition to leading process innovation, you will contribute to broader R&D initiatives in advanced materials and surface technologies, generate intellectual property, mentor junior researchers, and collaborate with engineering, manufacturing, analytical, and product development teams to accelerate the commercialization of innovative medical technologies.

Essential Duties and Responsibilities

• Lead the research, development, and scale-up of advanced materials manufacturing technologies with a primary focus on innovative syringe coating platforms and related medical device technologies.
• Develop novel manufacturing processes and surface engineering technologies from laboratory proof-of-concept through pilot-scale implementation, ensuring technical feasibility, robustness, and scalability.
• Identify, evaluate, and adapt advanced manufacturing technologies from adjacent industries—including semiconductor, electronics, aerospace, energy, automotive, and precision manufacturing—for application in medical device and healthcare products.
• Design, plan, and execute multidisciplinary research programs in advanced materials processing, surface modification, coatings, polymer processing, and functional materials.
• Develop and optimize manufacturing processes using scientific principles, Design of Experiments (DOE), statistical analysis, and data-driven decision making to improve process capability, reproducibility, and performance.
• Establish structure–process–property–performance relationships through advanced analytical characterization and correlate material and surface properties with device functionality and manufacturing performance.
• Lead the design, commissioning, qualification, and continuous improvement of laboratory and pilot-scale manufacturing equipment and processes.
• Collaborate with cross-functional teams including engineering, analytical sciences, manufacturing, quality, regulatory, and product development to enable successful technology transfer and commercialization.
• Provide technical leadership for complex research projects, serving as a subject matter expert in advanced materials manufacturing, surface engineering, and process innovation.
• Identify emerging technologies, scientific trends, and external collaborations that strengthen the organization's advanced manufacturing capabilities and long-term research strategy.
• Generate intellectual property through invention disclosures, patent applications, and publication of high-impact scientific research where appropriate.
• Mentor and provide technical guidance to scientists, engineers, research associates, and interns while fostering a collaborative and innovative research environment.
• Prepare technical reports, present research findings to senior leadership and external stakeholders, and communicate project progress, technical risks, and strategic recommendations.
• Contribute to strategic planning and portfolio development by identifying new technology opportunities aligned with organizational research priorities and future manufacturing capabilities.
• Ensure all research activities are conducted in compliance with applicable quality systems, safety requirements, regulatory expectations, and Good Documentation Practices (GDP).

Education

M.S. with 8+ years or Ph.D. with 3+ years of industrial R&D experience in Materials Science & Engineering, Chemical Engineering, Mechanical Engineering, or a closely related engineering or scientific discipline.

Work Experience

• Demonstrated experience developing novel materials processing or manufacturing technologies and translating them from laboratory to pilot-scale or manufacturing environments.
• Technical expertise in advanced materials processing, surface engineering, coatings, polymer processing, thin films, or related advanced manufacturing technologies.
• Proven experience in process development, optimization, and scale-up using scientific methods and data-driven approaches (e.g., DOE and statistical analysis).
• Experience leading multidisciplinary technical projects and collaborating effectively across research, engineering, and manufacturing organizations.
• Strong technical communication, problem-solving, and project management skills.

Preferred Knowledge, Skills and Abilities

• Advanced knowledge of materials processing, surface engineering, coatings, polymer processing, thin films, and advanced manufacturing technologies.
• Experience developing and transferring novel manufacturing technologies from adjacent industries (e.g., semiconductor, electronics, aerospace, energy, or precision manufacturing) to medical device or healthcare applications.
• Experience with laboratory-to-pilot-scale process development, technology transfer, and manufacturing scale-up.
• Strong understanding of process optimization, Design of Experiments (DOE), statistical analysis, and process characterization.
• Hands-on experience with advanced analytical and surface characterization techniques and correlating material properties with product performance.
• Demonstrated ability to identify emerging technologies and develop innovative technical solutions to complex research and manufacturing challenges.
• Experience generating intellectual property, including invention disclosures, patents, and technical publications.
• Proven ability to lead multiple research projects, mentor junior scientists and engineers, and influence technical direction across multidisciplinary teams.
• Excellent scientific communication, technical writing, and presentation skills.
• Ability to work independently while fostering collaboration across research, engineering, manufacturing, quality, and regulatory functions.