Principal Manufacturing Engineer

Boston Materials•Billerica, MA

About The Position

Boston Materials is seeking a Principal Manufacturing Engineer to serve as the technical lead for commissioning its high-volume manufacturing line as the company scales its Liquid Metal ZRT thermal interface material from bench-scale to high-volume production. The engineer will own the manufacturing process end to end, including commissioning, defining process windows and controls, and establishing production and quality systems to support aggressive ramp targets. The role partners closely with equipment and process engineering teams to turn novel materials processes into controlled, repeatable manufacturing. This is a senior, hands-on technical position rather than a supervisory role. The engineer will set the technical standard for manufacturing while providing direct support to the production line. The position is suited to someone who has taken a novel materials process from pre-pilot into production, can balance system-building with immediate problem-solving, and applies rigorous, data-driven manufacturing practices. The work contributes to thermal management solutions for next-generation AI and high-performance computing infrastructure.

Requirements

Bachelor's or Master's degree in Materials Science, Chemical Engineering, Mechanical Engineering, or a related discipline; equivalent hands-on experience is considered.
Hands-on experience taking a materials-based process from development or pre-pilot into a controlled manufacturing environment.
Ability to provide tactical, day-to-day engineering support to an active manufacturing line.
Ability to set equipment parameters and specification limits for critical-to-quality characteristics.
Experience implementing and maintaining QA/QC systems from raw material to finished product.
Experience developing and executing equipment qualification protocols (IQ/OQ/PQ).
Strong process control fundamentals, including SPC, control charts, and capability analysis.
Proficiency with manufacturing software, including Ignition/SCADA, Tulip/MES, and statistical tools such as Minitab or JMP.
Comfort working across engineering, operations, and quality in a fast-moving startup environment.
Must be currently authorized to work in the United States on a full-time basis.

Nice To Haves

Experience with specialty materials processing, such as liquid metals, composites, coatings, or advanced polymers.
Lean manufacturing experience applied to reducing waste and cycle time.
Six Sigma certification and experience with Measurement Systems Analysis (MSA).
Prior experience in a startup or early-stage manufacturing environment.

Responsibilities

Act as technical owner of the manufacturing process through commissioning of the high-volume line, from installation and IQ/OQ/PQ through full production readiness.
Design manufacturing and material flows, including robust flows for conforming and non-conforming material.
Establish line readiness, including base state, preventive maintenance plans, SOPs, and validated process windows.
Determine equipment parameters and specification limits for critical-to-quality characteristics, and design experiments to characterize process sensitivity.
Translate developmental materials processes into controlled manufacturing while preserving process intent.
Implement and configure MES, SCADA, and SPC tools for real-time monitoring and traceability.
Lead non-conformance investigations and root cause analysis, and drive corrective actions to closure.
Anticipate and eliminate execution risk and bottlenecks during an aggressive production ramp.
Drive continuous improvement of production and quality management systems.
Provide tactical engineering support to the active line.
Mentor engineers and technicians on process control and problem-solving.