Senior Process Engineer- Materials/Metallurgy

Position Summary

We are seeking a Senior Materials Science Engineer to lead the development, industrialization, and scale-up of Low Pressure Metal Injection Molding (LPMIM) technologies within Advanced Operations & Manufacturing.

This role plays a critical part in enabling next-generation medical device products — translating materials science innovation into scalable, high-volume, cost-optimized, and compliant manufacturing solutions. You will serve as the technical authority for LPMIM materials and processes, driving performance, reliability, and manufacturability from early concept through commercial production.

This is a high-visibility role partnering closely with R&D, Design Engineering, Global Manufacturing, Quality, and external suppliers to build differentiated manufacturing capability.

Key Responsibilities:
New Product Introduction (NPI) & Design Enablement

• Partner with R&D and Design Engineering to evaluate LPMIM feasibility for new components and assemblies.
• Lead Design for Manufacturability (DFM/DFA) reviews, translating product requirements into material, geometry, and process parameters.
• Define material selection strategies, feedstock composition, and downstream processing requirements to meet performance and regulatory standards.
• Develop and optimize LPMIM feedstocks, molding parameters, debinding profiles, and sintering cycles to achieve mechanical, chemical, and dimensional targets.
• Conduct advanced materials characterization (SEM, metallography, DSC/TGA, mechanical testing) to validate process capability and long-term reliability.
• Lead structured root cause investigations and implement sustainable corrective and preventive actions.
• Design and scale robust LPMIM processes for high-volume, cost-efficient production.
• Develop capacity models, cycle time analyses, and network-level scaling strategies.
• Integrate molding, debinding, sintering, and material handling systems into full production cells in partnership with global sites and suppliers.
• Lead mold and tooling strategy for high-volume LPMIM operations, focusing on thermal behavior, wear performance, and repeatability.
• Partner with suppliers through design, fabrication, FAT/SAT, and lifecycle management of tooling and capital equipment.
• Lead process validation activities (IQ/OQ/PQ) in compliance with FDA, ISO 13485, and internal quality systems.
• Drive PFMEA and risk mitigation strategies for material and process-related risks.
• Serve as the LPMIM subject matter expert across Advanced Operations, influencing technical decisions throughout the product lifecycle.
• Support pilot builds, engineering runs, and production ramp-up at global manufacturing sites.
• Champion Lean and Six Sigma initiatives to improve yield, reduce scrap, and optimize material cost.
• Identify and deploy emerging materials and technologies to advance LPMIM capability.

Minimum Qualifications

• Bachelor’s degree in Materials Science, Metallurgy, or related field.
• 2+ years of experience in Metal Injection Molding (MIM), powder metallurgy, thermally processed metals manufacturing or related duties.
• Master’s degree in Materials Science or related discipline is preferred.
• Demonstrated success scaling processes from prototype to high-volume production.
• Experience in medical device or other regulated, high-precision industries.
• Strong expertise in MIM materials science, sintering behavior, tooling principles, and feedstock design.
• Proficiency in CAD (SolidWorks or Creo) and simulation tools (mold flow, thermal analysis).
• Experience with validation protocols, DOE, SPC, and structured problem-solving methodologies.
• Six Sigma Green or Black Belt certification is preferred.
• Working knowledge of GD&T (ASME Y14.5).