The Senior Process Engineer will develop and optimize processes for existing and new manufacturing capabilities as part of Align’s world-leading Invisalign mass customization operation. They will drive step-change manufacturing improvements involving new technologies, materials, hardware and software. They will define and design new 3D printing processes to enhance efficiency and quality of products in the world’s largest 3D printing environment.

The Senior Process Engineer must be a leader, strategic thinker and problem solver. They must be organized, disciplined, and self-motivated, with the ability to balance multiple priorities related to operations and organization.

They must be able to communicate effectively and professionally with internal company personnel, as well as contractors or customers, and be able to network outside of their areas of expertise 

Key Responsibilities

• lead development, optimization, installation, and testing of new manufacturing technology and subsystems, with an emphasis on 3D printing.

• develop and optimize manufacturing processes with variable parameters using statistical methods

• independently execute feasibility studies and research and development projects related to manufacturing process improvements.

• analyze and improve processes for existing and new production methods involving new materials, new 3D printing technology, and new post-processing techniques.

• lead efforts on development and optimization of photopolymer printing systems

• lead, interact, and collaborate with other engineers including materials, software, mechanical, and electrical engineers.

• develop new prototype systems, processes, and test methods to enable new technology development

• work in a hands-on manner to quickly design and execute lab tests for assessing feasibility of new concepts and ideas.

• work with 3D modeling and print preparation software to design 3D printing experiments and validations.

• work with a production team to monitor unit operations, correct problems and assist in improvements to newly-developed technologies.

• lead the development, processing and testing of engineering materials to create products.

• lead research and development efforts with a focus on deliverables and accountability toward project plans

• work independently on complex challenges related to process engineering and data analysis

• actively mentor others and provide leadership to peers

• be responsible for design of new manufacturing equipment and capabilities and work with internal and/or external teams to deliver to production

Skills Knowledge & Expertise

• BS, MS, or PhD in a relevant engineering discipline (e.g. materials, mechanical, industrial, electrical, chemical) or related field

• 5+ years of experience in additive manufacturing (in academic and/or industrial environment)

• first hand experience with photopolymer printing (SLA, DLP, etc.)

• expertise in photopolymer materials 

• experience in 3D printing process development

• experience with design of experiments, statistical analysis

• strong communication, interpersonal and leadership skills.

• experience with 3D modeling and CAD

• experience and/or knowledge in statistics and process control

• ability to formulate sound, data-driven conclusions without direct supervision.

• ability to effectively present findings and respond to questions from groups of expert peers including managers, clients, customers and the general public.

• strong analytical skills to work on problems of diverse scope and determine root cause and path to solution

• ability to collaborate and work effectively with cross-functional teams to deliver project needs on schedule