Senior R&D Engineer (NDE)
EDISON WELDING INSTITUTE INC
Summary
EWI is seeking a Senior R&D Engineer to lead the application of advanced nondestructive evaluation (NDE) technology to client manufacturing challenges, with particular emphasis on integrating inspection into automated and in-process production systems. This is a customer-facing technical role. The successful candidate will work directly with client companies to define inspection problems, select and adapt leading-edge NDE methods, and implement those methods within robotic, automated, and in-line manufacturing environments. The position emphasizes application, integration, and deployment rather than fundamental research.
Job description
ESSENTIAL FUNCTIONS
Customer engagement and business development
- Serve as the primary technical point of contact for client companies on inspection and NDE projects; lead collaborative internal and external teams to implement solutions
- Visit client facilities to assess inspection needs, evaluate production environments, and identify opportunities for automated and in-process inspection
- Translate client requirements into project scopes, technical approaches, cost and schedule estimates
- Present findings, recommendations, and results to audiences ranging from shop floor operators to executive leadership
- Support business development through proposal preparation, technical presentations, client council participation, and industry conference activity
- Build long-term client relationships that lead to repeated and expanded work
- Train client personnel on delivered systems and transfer capability so solutions remain in use after a project closes
Technology implementation and automation
- Evaluate and select advanced NDE methods, including phased array and full matrix capture ultrasonics, eddy current array, computed tomography, thermography, guided wave, and optical techniques, and determine which are viable for production deployment
- Design and implement in-process and in-line inspection solutions that operate during manufacturing rather than after it, with emphasis on welding, additive manufacturing, and composite processes
- Integrate inspection hardware into robotic cells, gantries, motion systems, and production equipment, including sensor selection and placement, fixturing, scan planning, and instrument control
- Develop data acquisition, processing, and analysis pipelines, applying signal processing, image processing, and machine learning methods where they add value
- Interface inspection systems with plant control and quality data systems, and support feedback to the manufacturing process where feasible
- Validate system performance through designed experiments, probability of detection studies, and reliability analysis
- Develop procedures, work instructions, and qualification evidence to support customer, prime contractor, and regulatory acceptance
Project execution and technical leadership
- Manage project scope, budget, schedule, and deliverables, and produce clear technical reports and documentation
- Maintain current awareness of the commercial and academic NDE landscape, including instrument suppliers, research institutions, and standards development activity
- Contribute to EWI internal capability, tooling, and laboratory infrastructure
- Mentor junior engineers and technicians
Requirements
- Demonstrated experience implementing inspection or measurement systems within automated equipment, robotic cells, or production lines
- Working knowledge of at least one NDE modality, with practical familiarity across several
- Programming ability sufficient to build data acquisition, processing, and analysis tools, typically in Python or an equivalent language
- Experience designing and executing test programs and analyzing results statistically
- Proficiency in executing scientific research and performing experimental analysis
- Existing understanding of technical challenges in key markets including, but not limited to, oil and gas, power generation, heavy manufacturing, and automotive industries
- Utilizes judgment in communication styles and behaviors; recognizes impact on other team members
- Exhibits proficient written and verbal communication with customers both internal and external; including direct experience presenting technical work to customers
- Proven adaptability and flexibility as a part of team
- Ability to maintain excellent customer relationships both internal and external
- Proven success in a team-oriented environment
- Strong ability to plan and organize tasks
- Proficiency in Microsoft Office software
- Willingness to travel (10%) to customers and conferences
- Master's degree in engineering, physics, materials science, or a related technical discipline
- Five (5) or more years applying inspection, measurement, or sensing technology in a manufacturing, laboratory, or applied research environment
Company overview
Edison Welding Institute (EWI) is a leading nonprofit research and development organization specializing in advanced manufacturing technologies, with a primary focus on welding, materials joining, and engineering services. Founded in 1984 and headquartered in Columbus, Ohio, EWI serves as a critical resource for industry innovation, providing cutting-edge research, technical expertise, and workforce development programs. The organization operates as a collaborative research institute that bridges the gap between academic research and industrial application, offering solutions in areas such as nondestructive testing, materials science, and manufacturing process optimization. EWI's mission centers on advancing manufacturing technologies through sponsored research activities, government-funded projects, and industry partnerships. The institute generates revenue through government grants, program service fees, and membership dues, supporting its extensive research facilities and technical staff. As a federally registered tax-exempt corporation, EWI plays a vital role in enhancing U.S. manufacturing competitiveness by developing innovative welding technologies, improving production efficiency, and training the next generation of manufacturing professionals. The organization's work spans multiple industries including aerospace, automotive, energy, and defense sectors, making significant contributions to materials engineering and industrial innovation.