Senior Process Engineer

Senior Process Engineer | Boston, MA | $120 - 180k

We are partnered with a company that produces advanced materials with enhanced energy transfer properties using its patented Z-axis Carbon Fiber technology. The company's products address critical performance bottlenecks across thermal, electrical, and structural applications. Its breakthrough Liquid Metal ZRT thermal interface material is engineered to solve the thermal challenges facing the next generation of AI and HPC silicon.

The Role

The New Product Introduction (NPI) team is seeking an experienced Senior Process Engineer to help transform cutting-edge R&D into reliable, production-ready manufacturing processes. In this role, you'll partner closely with Engineering and Operations to translate innovative process development into clear, repeatable manufacturing procedures that support the next generation of our thermal interface materials.

You'll own critical aspects of process control and data analysis, implementing rigorous monitoring systems to identify trends, uncover root causes, and optimize performance while meeting demanding safety, capacity, and yield targets. This role goes beyond maintaining stable operations, it's about solving complex technical challenges, removing process bottlenecks, and enabling manufacturing processes to successfully scale to high-volume production.
If you're energized by troubleshooting complex systems, validating innovative concepts, and building manufacturing processes that perform reliably in real-world production, we'd love to hear from you.

Your Responsibilities

• Design and optimize novel chemical and materials processes for the commercial production of advanced materials.
• Deliver key Release-to-Manufacturing milestones and support capacity scaling across new manufacturing and quality processes.
• Develop and execute Design of Experiments (DOE) to improve process understanding and increase process stability, capability, and scalability.
• Perform root cause analysis to identify and eliminate assignable cause variation.
• Identify, select, and implement instrumentation, controls, and process monitoring systems needed to characterize materials and processes and achieve development objectives.
• Design new process equipment or modify commercially available equipment to meet process requirements, leading internal teams and external vendors through implementation.
• Partner with the Operations team to develop and implement workflow improvements.
• Collaborate with Quality Engineering to establish quality metrics that ensure product form, fit, and function.
• Lead Process FMEA activities for new manufacturing processes.
• Demonstrate exceptional standards of safety, organization, communication, and documentation.
• Implement 6S principles across production equipment and workstations.
• Thrive in a startup or small company environment by embracing challenges, adapting to change, and continuously seeking improvements.

Your Skills and Expertise

• Bachelor's or Master's degree in Chemical Engineering or Materials Science strongly preferred; equivalent experience will be considered.
• Demonstrated success developing chemical processes, roll-to-roll systems, and other continuous manufacturing processes.
• Hands-on experience performing hazard analyses, establishing engineering controls, and ensuring the safe operation of complex manufacturing processes.
• Strong understanding of sensing technologies and data acquisition methods for process monitoring and control.
• Commitment to 6S principles and maintaining clean, organized, and efficient work environments.
• Proven track record of leading continuous improvement initiatives that increase throughput, quality, and operational reliability.
• Experience conducting Process FMEAs to identify risks, prioritize mitigation strategies, and improve process robustness.
• Strong foundation in applied statistics, including capability analysis, control charts, ANOVA, and hypothesis testing.

Summary of Benefits

• Health, Vision & Dental – Boston Materials covers 75% of health, vision, and dental insurance premiums for employees and their dependents.
• Four weeks of supplemental Paid Parental and Family Leave.
• Unlimited Paid Time Off.
• 14 paid holidays per year.

Compensation: $120,000 – $180,000 per year