Foam Process Engineer

JB Poindexter & Co•Morgantown, PA

1d•Onsite

About The Position

Put your process expertise to work where it makes an impact. As a Foam Process Engineer, you’ll optimize polyurethane foam production processes, troubleshoot equipment and material challenges, and use data to drive improvements in quality, consistency, safety, and productivity. Working hands-on with resin and isocyanate systems, you’ll partner across Manufacturing, Quality, and Engineering to solve problems and continuously improve performance.

Requirements

Bachelor’s degree in Chemical, Mechanical, Manufacturing, Materials Engineering, or a related technical field preferred; equivalent education and relevant experience considered.
5+ years of experience with polyurethane foam systems, chemical processing, or automated dispensing equipment preferred.
Understanding of polyurethane chemistry, resin/isocyanate systems, and foam manufacturing processes.
Experience with meter-mix-dispense systems, PLC-controlled equipment, and process monitoring, including troubleshooting mixing and dispensing systems.
Ability to analyze process data, apply statistical methods, and use root cause analysis to solve manufacturing challenges.
Experience in transportation, automotive, construction products, refrigeration, or a similar manufacturing environment preferred.
Proficiency with Microsoft Office and manufacturing data systems.
Ability to travel approximately 50% across manufacturing locations in the U.S. and Canada.

Responsibilities

Monitor and optimize polyurethane foam dispensing and mixing processes, including resin/isocyanate ratios, temperatures, pressures, flow rates, and shot weights.
Audit foam processing equipment, troubleshoot issues with Maintenance, and establish preventive maintenance and calibration standards.
Ensure foam meets established density, adhesion, dimensional stability, fill, and performance requirements.
Investigate foam defects-including voids, shrinkage, adhesion, density, fill, and delamination issues-and implement effective corrective and preventive actions.
Improve formulations, application methods, and process parameters to increase yield, material utilization, cycle time, scrap performance, and process capability.
Analyze production and quality trends, conduct capability studies, and support process validation activities.
Partner with suppliers to evaluate raw material performance, resolve resin and isocyanate issues, and qualify new chemicals, suppliers, and equipment.
Provide foam process expertise for new product development, trials, and manufacturing implementation.
Maintain SOPs, work instructions, control plans, specifications, and quality records while ensuring compliance with chemical-handling and EHS requirements.
Serve as the polyurethane foam subject matter expert, providing hands-on troubleshooting, training, and technical support to Production, Maintenance, and Engineering teams.