Sr. Application Engineer

Tegra Medical•Franklin, MA

1d•$96,000 - $120,000•Onsite

About The Position

The Senior Application Engineer is a strategic technical leader who evaluates and defines the cost structure of new and legacy medical device manufacturing projects. The role defines optimal manufacturing sequences, assesses production feasibility and required internal and external technologies, and provides recommendations that inform product introduction and scaling strategies. The position provides high-level Design for Manufacturability (DFM) guidance, leads cost modeling, and connects customers, engineering, sales, and production from early quoting through full-scale manufacturing to ensure technical and financial alignment. The employee is required to work onsite at the assigned company location. The role also provides technical leadership to Application Engineers and serves as a subject matter expert on manufacturing processes, materials, equipment, and external services.

Requirements

At least 8 years in manufacturing, processing, or applications engineering, or cost estimating; preferably in medical device or precision manufacturing.
Proven technical leadership directing complex, cross-functional quoting and mentoring engineers.
Strong business acumen balancing cost, quality, risk, lead time, and customer expectations.
Extensive knowledge of precision manufacturing processes, materials, inspection methods, and external services.
Experience evaluating new technologies, including supplier engagement, trials, and make-versus-buy recommendations.
Ability to develop capability assessments and business cases.
Advanced skills in engineering drawings, GD&T, specifications, and DFM principles.
Demonstrated ability to develop detailed cost models and present customer-ready proposals with scenario and sensitivity analyses.
Strong analytical and problem-solving skills, including the ability to work with incomplete or conflicting information.
Excellent written, verbal, and presentation skills.
Project-management skills to handle multiple complex RFQs and meet deadlines.
Experience improving quoting processes through standard work, data analysis, and lessons learned.
Proficiency with ERP, quoting and cost-modeling tools, Excel, Word, and PowerPoint; ability to manage large datasets.
Bachelor's degree in mechanical engineering, manufacturing engineering, or a related technical field, and excellent mechanical/manufacturing aptitude.

Nice To Haves

SolidWorks/CAD experience is strongly preferred.
Advanced training or certifications in cost estimating, lean manufacturing, or DFM/A are highly desirable.

Responsibilities

Lead complex quotes for medical device components and assemblies by reviewing RFQs, specifications, and drawings; coordinating cross-functional input; and determining feasibility, manufacturing strategy, risk, lead time, and cost.
Lead quote strategy and technical reviews for high-value, high-risk opportunities, communicating recommendations, tradeoffs, assumptions, and cost drivers to customers, Sales, and management.
Provide technical leadership to Application Engineers by setting priorities, reviewing work, resolving gaps, and ensuring accurate, timely quotes.
Provide strategic DFM guidance and create CAD models or drawings to improve manufacturability, reduce cost, and meet quality and regulatory requirements.
Serve as a subject matter expert on manufacturing processes, materials, equipment, and external services.
Investigate new technologies, processes, materials, and suppliers when requests exceed current capabilities; coordinate trials, supplier consultations, and subject-matter-expert reviews.
Develop capability assessments and business cases addressing feasibility, validation, risk, tooling, capital, and ROI; recommend whether to develop internally, source externally, or exclude an opportunity.
Build and validate detailed cost models for components, subassemblies, and finished assemblies, including multilevel BOMs, routings, setup and cycle times, labor and machine assumptions, yield and scrap, tooling, validation, inspection, packaging, outsourced services, and capital.
Prepare customer-ready proposals documenting scope, pricing logic, volumes, nonrecurring engineering, tooling, lead times, exclusions, risks, and sensitivity analyses.
Collaborate with suppliers and internal teams to ensure estimates are defensible, commercially aligned, and on schedule.
Support handoff of awarded projects to development and production, ensuring receiving teams own assumptions, cost targets, risks, and commitments.
Maintain cost integrity by comparing quoted assumptions with actual performance and applying lessons learned.
Improve quoting through data analysis, standard work, capability mapping, and maintenance of material, process, cost, and lead-time databases.
Coach Application Engineers on quoting, DFM, and cost-modeling standards.