Senior Development Engineer - Modeling & Simulation

Role Purpose

Corning is seeking a Senior Development Engineer to apply finite element and computational modeling to improve optical fiber manufacturing at our Wilmington, NC plant. You will build models grounded in real process data and turn the results into implemented process and equipment improvements that raise yield, throughput, quality, and energy efficiency. This is a hands-on role in the plant with minimal travel (less than 5%). You will collaborate with technology development, process engineering, and manufacturing teams to improve yield, throughput, product quality, raw material efficiency, and energy usage

Key Responsibilities

• Develop, validate, and maintain thermal, structural, and computational fluid dynamics (CFD) models of glassmaking processes and equipment using commercial tools such as ANSYS, COMSOL, and Fluent
• Work hands-on in the plant to gather process data, run experiments and trials, and use the results to calibrate and validate models
• Use physics-based analysis to identify root causes of process limitations, and translate results into engineering requirements, design recommendations, and process windows
• Evaluate design and process alternatives both virtually and hands on to reduce development time, cost, and risk; support troubleshooting, process changes, and equipment start-up and qualification
• Partner with technology development, process engineering, and manufacturing teams to improve yield, throughput, quality, and energy use; document findings and present recommendations to leadership

Additional Information

• Location: Wilmington, NC (relocation assistance is available)
• Hours of Work: 40+hours per week, primarily 8AM to 5PM schedule with flexibility based upon personal preference and project need. 
• Travel Requirements: <5% domestic and international possible

Experiences/Education - Required

• Masters in Physics, Mechanics, Mechanical Engineering, Applied Mathematics, or a related field (e.g., solid mechanics, fluid dynamics, theoretical physics)
• 5+ years of relevant experience after the highest degree.
• Demonstrated experience applying FEM/FEA to industrial or manufacturing problems.
• Expertise in finite element methods (FEM/FEA) and computational modeling of physical phenomena (mechanics, heat transfer, fluid flow).
• Working knowledge of major commercial CAE software such as ANSYS, COMSOL Multiphysics, and/or Fluent.
• Demonstrated process engineering experience in a manufacturing or pilot-scale environment.
• Willingness and desire to work in a plant environment, applying modeling directly to real manufacturing problems.
• Bias for action: self-driven, action-oriented, and effective in situations of uncertainty.
• Strong willingness to learn new things – processes, equipment, tools, and disciplines outside of core expertise.
• Proven problem-solving skills using scientific methods, root cause analysis, and well-designed experiments.
• Ability to work independently and collaboratively on cross-functional teams and carry assignments through to completion.

Experiences/Education - Desired

• Experience validating models against experimental and plant data, including uncertainty and sensitivity analysis
• Multiphysics experience (coupled thermal, structural, and fluid), radiative heat transfer, or modeling of high-temperature or glass processes
• Programming or scripting for modeling and data analysis (for example Python, MATLAB, or ANSYS Parametric Design Language), plus JMP, Power BI, and Microsoft Office
• CAD experience (for example SolidWorks or Autodesk)
• Experience with optical fiber manufacturing processes or equipment
• Experience leading technical teams or projects