Process Development Engineer

Boston Materials • Billerica, MA

16h

About The Position

Boston Materials produces advanced materials with enhanced energy transfer properties using its patented Z-axis Carbon Fiber technology. The Company's products solve critical performance bottlenecks in applications spanning thermal, electrical, and structural use cases. Its breakthrough Liquid Metal ZRT thermal interface material is designed for the most demanding AI Infrastructure. Boston Materials is committed to expanding high-volume manufacturing in the United States.

The Role Boston Materials’ New Product Introduction (NPI) team is looking for an experienced Process Development Engineer who can turn cutting-edge R&D into reliable, production-ready manufacturing. In this role, you’ll work closely with Engineering and Operations to translate new processes into clear, repeatable procedures that support our next generation of thermal interface materials. You’ll own the details of process control and data analysis, implement rigorous monitoring to spot patterns, uncover root causes, and push systems to meet high safety, capacity, and yield targets. This work isn’t just about maintaining stability, it’s solving hard problems, removing bottlenecks, and unlocking the keys to scaling production processes to high-volume operations. If you’re driven by troubleshooting complex systems, validating bold ideas, and building processes that stand up to real-world production, this is the place to do it.

Requirements

• Bachelor's or Master’s degree in Chemical Engineering or Materials Science strongly preferred; equivalent experience considered.
• Demonstrated success developing chemical processes, roll-to-roll systems, and other continuous manufacturing workflows.
• Hands-on ability to perform hazard analyses, define engineering controls, and ensure safe operation of complex processes.
• Strong understanding of sensing technologies and data acquisition methods for process monitoring and control.
• Commitment to 6S principles and building clean, organized, and efficient work areas.
• Consistent track record of driving continuous improvement initiatives that raise throughput, quality, and reliability.
• Ability to perform process FMEAs to identify risks, prioritize mitigations, and strengthen process robustness.
• Solid grounding in applied statistics, including capability analysis, control charts, ANOVA, and hypothesis testing.

Responsibilities

• Design and optimize novel chemical/materials processes for commercial production of advanced materials.
• Deliver key Release-to-Manufacturing milestones and capacity scaling across new manufacturing and quality processes.
• Develop and execute DOE’s that improve understanding of process fundamentals and ultimately lead to increases in process stability, capability, and scale.
• Perform root cause analysis and resolution of assignable cause variation.
• Identify, select, and implement instrumentation, controls, etc. to enable process and material characterization necessary to achieve developmental goals.
• Conceive new process equipment designs or modifications to commercially available equipment to suit process requirements.
• Lead activities of external vendors or internal counterparts to execute these designs/modifications.
• Assist Operations team in devising and implementing workflow improvements.
• Work with quality engineers to establish quality metrics that assure product form, fit, and function.
• Lead process FMEA for new processes.
• Conspicuously exemplify high standards of safety, organization, communication, and documentation.
• Implement 6S for production equipment and workstations.
• Work effectively in a startup or small company setting.
• Embrace challenges, adapt to changes, and continuously seek to improve.

Benefits

• Health, Vision & Dental – Boston Materials pays 75% of Health, Vision and Dental Care coverage for employee and dependents
• 4 weeks of supplemental Paid Parental and Family Leave
• Unlimited Paid Time Off
• Holidays: 14 days/year

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Education Level: Associate degree