Senior Process Engineer- MaterialsMetallurgy

What we want:

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.

Materials & Process Development

• 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.

Manufacturing Scale-Up & Integration

• 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.

Tooling & Equipment Leadership

• 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.

Validation Compliance & Quality Systems

• 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.

Technical Leadership & Continuous Improvement

• 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:

• Bachelors 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.

Preferred Qualifications:

• Masters degree in Materials Science or related discipline.

• 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.

• Working knowledge of GD&T (ASME Y14.5).