Senior Process Engineer- Materials/Metallurgy

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.

• 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.

• 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.

• 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).