Principal Process Engineer, Additive Manufacturing

Medtronic • Warsaw, IN

6d • $131,200 - $196,800 • Hybrid

About The Position

This role is for a Principal Process Engineer specializing in Additive Manufacturing at Medtronic, a global leader in healthcare technology. The engineer will be part of the Manufacturing Innovation and Technology team, focusing on driving additive manufacturing capabilities across the operations network. The role involves optimizing and scaling existing metal additive processes, maturing new technologies through testing and validation, and leveraging expertise in laser-based powder bed fusion (L-PBF), parameter development, and material characterization to deliver scalable manufacturing solutions. The position is based in Warsaw, Indiana, and requires up to 25% travel. Medtronic emphasizes a mission-driven approach, innovation, and employee growth, offering a collaborative and impactful work environment.

Requirements

• 7+ years of experience with a bachelor’s degree or 5+ years of experience with an advanced degree
• Bachelor’s or Master’s degree in Chemical, Materials, or Biomedical Engineering, with experience in medical device or pharmaceutical development.
• For Baccalaureate degrees earned outside of the United States, a degree that satisfies the requirements of 8 C.F.R. § 214.2(h)(4)(iii)(A) is required.

Nice To Haves

• Deep technical expertise in metal additive manufacturing, including Laser Powder Bed Fusion (L-PBF), process parameter development, metallurgical principles, and manufacturing process optimization.
• Hands-on experience with advanced materials characterization and testing methods, including Micro-CT, scanning electron microscopy (SEM), fractography, and mechanical property evaluation to assess process capability and material performance.
• Demonstrated expertise in additive manufacturing technologies, software platforms, and emerging industry advancements, including evaluation of new equipment, processes, and manufacturing capabilities for future applications.
• Experience designing and developing new technology solutions ahead of formal development projects.
• Ability to manage multiple projects, analyze data accurately, and apply statistical or sensitivity analysis.
• Familiarity with design controls, product and process validation, and the medical device PDP cycle in a regulated environment.
• Proven ability to collaborate with global partners and stakeholders; willingness to travel up to 25%.

Responsibilities

• Develop and maintain deep technical expertise in metal additive manufacturing (including Laser Powder Bed Fusion), technical ceramics, and advanced material characterization methods to guide technology development and capability advancement.
• Lead process optimization, experimental evaluations, and characterization activities using advanced analytical techniques and design of experiments (DOE) methodologies to improve process capability, material performance, and manufacturing readiness.
• Collaborate with internal and external subject matter experts to develop, integrate, and optimize end-to-end manufacturing workflows, including additive manufacturing, post-processing, machining, surface finishing, and technology transfer into production environments.
• Translate voice of customer (VOC), voice of research (VOR) and voice of business (VOB) feedback into manufacturing technology development strategy.
• Coordinate and oversee technology feasibility and testing activities both at the vendor and within Medtronic facilities.
• Communication of technical capability assessments, strategy, and value proposition to wide audiences, including operations innovation senior leadership.
• Collaborate with dispersed network of teams of engineers and technical staff to influence additive metals and machining manufacturing strategies.
• Appropriately documents strategy and business cases for annual investment and transfer of technology into development. Translate research strategy and investments into significant operations value.
• Provide guidance and mentorship to junior engineering staff.
• Designs, develops, analyzes, troubleshoots and provides technical skills during research and/or product development.
• Designs studies to investigate specific life science questions within field of expertise.
• May be involved in product research and development and/or clinical trials.
• Translates research discoveries into usable and marketable products.

Benefits

• Competitive Salary and flexible Benefits Package
• Health, Dental and vision insurance
• Health Savings Account
• Healthcare Flexible Spending Account
• Life insurance
• Long-term disability leave
• Dependent daycare spending account
• Tuition assistance/reimbursement
• Simple Steps (global well-being program)
• Incentive plans
• 401(k) plan plus employer contribution and match
• Short-term disability
• Paid time off
• Paid holidays
• Employee Stock Purchase Plan
• Employee Assistance Program
• Non-qualified Retirement Plan Supplement
• Capital Accumulation Plan (available to Vice Presidents and above, or subject to IRS earning minimums)

What This Job Offers

• Job Type: Full-time
• Career Level: Principal