Senior Materials & Process Engineer

Salary Range: 140000 to 190000 (Currency: USD) (Pay period: per-year-salary)

What you'll be doing:

• Complex Part Engineering 
• Engineer solutions for producing parts with complex geometries, tight tolerances, and demanding specifications. 
• Solve process design challenges for parts with undercuts, variable wall thickness, multi-material construction, and precision features. 
• Develop approaches for parts that others consider unmanufacturable, with focus on volume production capability. 
• Work with advanced polymer and composite materials to create high-performance components for large-scale manufacturing. 
 
• Problem-Solving Through Equipment Development 
• Build whatever equipment is needed to make complex parts work - forming presses, custom tooling, specialized fixtures, and high-throughput processing equipment 
• Create SolidWorks models and detailed drawings with proper GD&T for tooling and equipment designed for high volume processes. 
• Machine, weld, and assemble custom solutions when off-the-shelf equipment won't suffice for production requirements 
• Prototype rapidly until parts meet specifications consistently and processes are ready for scale-up 
 
• Part Development & Manufacturing Solutions 
• Take on part challenges that require innovative manufacturing approaches capable of high-volume production 
• Design and build forming processes for complex brackets, housings, structural components, and precision assemblies with polymer and composite materials 
• Solve inserts, handling, and quality control challenges for difficult geometries in production environments 
• Develop repeatable, high-volume processes for complex parts that can efficiently scale to large production runs 
 
• Hands-On Implementation 
• Build and test whatever tools, fixtures, and equipment are needed to make parts work at production volumes 
• Troubleshoot part quality issues and implement design solutions for volume manufacturing 
• Work directly with prototype parts to understand manufacturing constraints and scale-up opportunities for polymer and composite components 

What you will bring to this role:

• Bachelor's degree in Mechanical Engineering, Materials Engineering, or related technical field 
• 3-6 year's experience solving complex part manufacturing challenges with focus on scalable processes 
• Expert-level SolidWorks skills including advanced modeling, drawings, and GD&T application 
• Experience with advanced materials and high-volume forming processes such as thermosets, thermoplastics, elastomers. 
• Hands-on fabrication skills: machining, welding, assembly, and creative problem-solving 
• Track record of solving challenging manufacturing problems while maintaining production viability 

Essential Skills:

• Part-focused thinking: ability to reverse-engineer manufacturing solutions from part requirements with volume production in mind 
• SolidWorks: advanced modeling for complex parts and custom tooling solutions designed for production scale 
• GD&T: proper application for complex parts with challenging tolerance requirements in volume manufacturing 
• Creative problem-solving: building non-standard solutions for unique part challenges that work at scale 
• Hands-on fabrication: whatever skills are needed to make the solution work in production 
• Materials expertise: understanding polymer and composite material behavior in complex, high-volume forming applications 
• Production scaling: experience transitioning prototype processes to efficient, large-volume manufacturing 

What Sets You Apart:

• You see a complex part and immediately start thinking about how to make it efficiently at volume 
• You're not limited by existing equipment - you build what's needed to solve the problem for production scale 
• You thrive on part challenges that others walk away from, especially when volume production is required 
• You understand that the equipment is just a tool to achieve the real goal: perfect parts at production quantities 
• You can take a challenging part specification and deliver a working manufacturing solution ready for large-scale production 
• You think about scalability, cycle times, and production economics from day one 
• Collaborative environment with part designers, manufacturing teams, and production engineers 

Additional Requirements

This is a fast-paced, high-impact environment - flexibility to occasionally work extended hours or weekends during critical periods is expected.