Senior Process Engineer - Materials Processing

About LightForce Orthodontics

LightForce Orthodontics is a technology company focused on a new era of personalized orthodontics that launched the world's only fully customized digital bracket system in 2019. Our ecosystem combines precisely manufactured 3D-printed braces and digital treatment planning software empowering orthodontists to deliver remarkable results. We are proud to be one of the fastest growing companies in the industry. Learn more at www.lf.co

Description

We are looking for a Senior Process Engineer with expertise in materials science and slurry-based additive manufacturing to join our Process Engineering team. You will join a growing team that is designing and implementing advanced manufacturing processes that enable high-volume production of customized medical devices. Our ideal teammate communicates effectively, is process and data-driven, works well under pressure, and is eager to continue learning.

The Senior Process Engineer will be responsible for leading the development, optimization, and scaling of post-processing methods for our slurry-based additive manufacturing technologies. The ideal candidate will have a deep understanding of materials science, process engineering, and additive manufacturing.

As a senior member of the process engineering team, your expertise and guidance will be an important driver for our success. The strategic roadmap for project execution will be driven by your input and decision making.

Essential Duties and Responsibilities

• Materials Processing: Lead the design, development, and optimization of post-processing methods (cleaning, sintering, surface finishing) for additively manufactured parts. Transition processes from lab to full-scale production, ensuring feasibility and performance.
• Material Characterization and Testing: Utilize various test and inspection methods (e.g. hardness testing, tensile testing, profilometry, pycnometry, viscometry etc.) as well as analytical techniques (e.g. SEM, TGA) to support process development and qualification.
• Process Optimization: Identify opportunities to optimize and automate processes to improve quality, efficiency and cost. Utilize data-driven approaches and statistical methods to analyze process performance, identify trends, and develop actionable insights.
• Project Leadership: Lead projects related to the development and scaling of new processes, ensuring alignment with business goals, timelines, and budget constraints.
• Collaboration and Mentorship: Work closely with R&D, production, and quality teams to ensure seamless integration of new processes and materials.

Education and Experience

• Bachelor’s degree in Materials Science, Chemical Engineering, Mechanical Engineering or a related field and minimum 8 years of relevant industry experience, OR
• Master’s degree and minimum 6 years of relevant industry experience, OR
• PhD degree and minimum 3 years of relevant industry experience

Required Qualifications

• Technical Skills: Strong knowledge of materials science and its application to slurry-based ceramic or metal additive manufacturing or powder metallurgy, including solvent-based cleaning, sintering and heat treatment, and surface treatment.
• Analytical Abilities: Exceptional problem-solving skills with the ability to analyze complex data and develop effective solutions. Experience with statistical analysis and data-driven decision-making.
• Hands-on experience: Experience working in a lab or similar environment; general knowledge of safety protocols relevant to materials processing and manufacturing.
• Communication Skills: Excellent verbal and written communication skills, with the ability to collaborate across teams and convey complex material science concepts to diverse audiences.

Preferred Qualifications

• Experience with medical device qualification protocols including IQ/OQ/PQ
• Experience working in a startup environment
• Experience with project management methodologies and tools

Physical Demands

• Requires the ability to use hands and reach with hands and arms
• Requires the ability to see, listen, and speak
• Requires work activities with production chemicals, adhesives and epoxies, using required personal protective equipment
• Requires walking and standing for long periods of time

Perks and Benefits (US Employees Only)

• Unlimited PTO for exempt employees
• 10 paid holidays per year
• Generous premium coverage for medical and dental plans
• Access to employee paid vision plan
• Group plan voluntary life insurance
• Fringe benefits
• 401k retirement plan
• Paid parental leave
• Workplace perks such as food/coffee

We are committed to building a diverse and inclusive company and we are most interested in finding the best candidate for the job. We would strongly encourage you to apply, even if you don't believe you meet every one of the preferred qualifications described.

LightForce Orthodontics is an Equal Opportunity/Affirmative Action Employer and does not discriminate on the basis of race, color, religion, gender, age, national origin, disability, Protected Veteran status, sexual orientation, or any other characteristic protected by federal, state, or local law.