Principal Development Engineer - Single-Use Film Development

Merck•Bedford, MA

About The Position

The Principal Development Engineer leads hands-on development and technical stewardship of MilliporeSigma’s Single-Use Life Science film solutions. You will drive innovation across multi-layer film technologies, oversee process development from concept to scale-up, and ensure quality, regulatory compliance, and manufacturing efficiency. This role requires strategic thinking, cross-functional collaboration, and a strong focus on safety and continuous improvement.

Requirements

MS degree in Plastics Engineering, Polymer Science, Film Technology, or related field (or equivalent); 10+ years of industry experience with proven expertise in single-use film development.
Demonstrated success managing complex film processes and new product development.
Strong knowledge of blown, cast, and extrusion film equipment and roll-to-roll operations; experience with laminated and multi-layer film structures and embossing is advantageous.
Solid understanding of quality systems, regulatory requirements, and corrective action processes.
Experience supervising third-party manufacturing relationships and ensuring technical transfer quality.

Nice To Haves

PhD or additional advanced degree; professional certifications (e.g., Six Sigma, PMP, NEBOSH/OSHA) related to film technology, quality, or safety.
Deep experience with laminated/multi-layer film structures and embossing techniques; hands-on regulatory compliance in life sciences film materials.
Proficiency with ERP/WMS and data-driven decision making for process optimization.
Strong cross-functional collaboration experience, with ability to influence external partners and internal stakeholders.
Global/regional exposure and understanding of international regulatory standards and best practices.

Responsibilities

Lead development and scale-up of blown, cast, extrusion, laminated, and multi-layer films for single-use applications.
Oversee roll-to-roll processing, embossing, and incorporation of advanced features using vision systems.
Formulation: select, evaluate, and qualify resins and additive packages.
Provide subject-matter expertise on roll-to-roll processing and advanced film features; guide process optimization and technology transfer.
Manage end-to-end process development including quality control, troubleshooting, and corrective actions.
Ensure compliance with regulatory standards relevant to film materials in life sciences.
Collaborate closely with third-party manufacturing partners, providing technical direction and oversight.
Drive continuous improvement initiatives to optimize film performance, quality, and manufacturing efficiency.