Sr. Process Development Engineer

Meet the team

The Sensor Process Development team develops and improves the manufacturing processes and equipment used to produce Dexcom continuous glucose monitoring sensors. We work across the product lifecycle, from early process development and equipment concepting through characterization, validation, technology transfer, and production support. In this role, you will connect process science with practical equipment solutions to improve sensor performance, manufacturing robustness, and scalability across global operations.

Where you come in

• You will develop, characterize, optimize, and transfer end-to-end glucose sensor manufacturing processes from concept through production implementation.
• You will design and execute process characterization studies and Design of Experiments (DOE) to establish critical process parameters, operating windows, and process controls.
• You will translate product and process requirements into equipment specifications and partner with equipment, automation, controls, software, and vendors to develop scalable manufacturing solutions.
• You will lead technical workstreams for equipment design reviews, testing, qualification, validation, deployment, and manufacturing readiness.
• You will analyze development and production data to improve process capability, yield, throughput, equipment reliability, and product quality.
• You will lead structured root cause investigations for complex process, equipment, and sensor performance issues and implement sustainable corrective actions.
• You will support new product introduction, manufacturing scale-up, and technology transfer between development teams and global manufacturing sites.
• You will create clear technical documentation, including requirements, protocols, reports, procedures, risk assessments, and process FMEAs, while providing technical guidance to engineers and cross-functional partners.

What makes you successful

• You have demonstrated hands-on experience developing and improving complex manufacturing processes in a medical device, biosensor, semiconductor, life science, or other regulated environment.
• You understand how materials, process parameters, equipment performance, environmental conditions, and test methods interact to influence product performance and manufacturing variability.
• You have strong proficiency in statistical analysis, DOE, process capability, Statistical Process Control, test method development, and data-driven problem solving using tools such as JMP or Minitab.
• You have experience defining user and process requirements and supporting the design, build, integration, qualification, and deployment of custom manufacturing equipment or automation.
• You are skilled in root cause analysis, risk management, process validation, and technical documentation within a quality system.
• You can lead complex technical projects, manage competing priorities, communicate recommendations clearly, and drive alignment across R&D, Manufacturing, Quality, Automation, Equipment Engineering, and Operations.
• You are comfortable working hands-on in laboratory and manufacturing environments and can move effectively between detailed technical analysis and practical implementation.
• Your experience with glucose sensors, electrochemical biosensors, coating or dispensing processes, curing, calibration, environmental controls, global technology transfer, or high-volume manufacturing is preferred.

Travel Required

15-25%

Experience and Education Requirements

Typically requires a Bachelor’s degree in a technical discipline, and a minimum of 5-8 years related experience or Master’s degree and 2-5 years equivalent industry experience or a PhD and 0-2 years experience.