Senior Materials Engineer, Thermoplastics and Compounding

Lyten•San Jose, CA

3d•$116,600 - $175,000

About The Position

Lyten is hiring a Senior Materials Engineer to develop and commercialize advanced thermoplastic compounds and 3D-printing filaments. The role owns the upstream portion of product development: designing formulations, compounding and testing materials, evaluating them through printing, and delivering an initial product ready for launch handoff. The engineer partners with the Product Manager, who leads launch and commercial support, and remains accountable for material performance during printing and use. The work spans materials science, manufacturing, and customer applications. The engineer diagnoses compounding, printing, and performance issues; determines whether root causes relate to materials, processes, or applications; and develops practical solutions. The focus is on engineering and shipping reliable products rather than open-ended research. Prior additive manufacturing experience is not required, but depth in compounding and processing is essential. The position involves production-floor work and travel to supplier sites of approximately 10 percent. The stated base salary range is $116,600 to $175,000. The position is eligible for a tier-based bonus and equity, healthcare, dental and vision coverage, corporate discounts, paid holidays, PTO and sick time, a 401(k), and an employee relocation plan if applicable. The role requires compliance with applicable export-control restrictions and continued government authorization where required.

Requirements

BS with at least 5 years of experience, MS with at least 3 years of experience, or PhD in Polymer Science, Polymer or Chemical Engineering, Materials Science, or a related field.
Working knowledge of polymer structure-property relationships and polymer rheology, with the ability to apply them to production and development problems.
Hands-on thermoplastic compounding and melt-processing experience, particularly twin-screw extrusion, in a production or scale-up setting.
Demonstrated engineering problem-solving, including structured root-cause analysis such as DOE, failure analysis, or process characterization, and a record of resolving issues.
Experience with thermoplastic fillers and additives, such as glass fiber, carbon fiber, carbon nanotubes, or graphene, including their dispersion and effects on processing and properties.
Familiarity with polymer characterization methods, including rheology, thermal analysis, and mechanical testing, and the ability to interpret and act on results.
Ability to run and interpret 3D-printing tests, with familiarity with FFF/FDM printing.
Comfort working on a production floor and traveling to supplier sites, approximately 10 percent.
Clear written and verbal communication with suppliers and internal teams.

Nice To Haves

In-depth experience with 3D printing or additive manufacturing, particularly FFF/FDM filament.
Experience with filament extrusion, including diameter control and spooling.
Familiarity with engineering thermoplastics such as PA, PC, PEEK, or PEI.
Experience taking thermoplastic products from development through manufacturing.
Customer-facing or applications engineering experience.
Working knowledge of ASTM/ISO polymer test standards.
Experience working with contract manufacturers, including audits and corrective-action processes.
Ability to make and defend technical tradeoff decisions involving cost, quality, and schedule.

Responsibilities

Design and develop thermoplastic and filament formulations, selecting resins, fillers, and additives to meet performance, processability, and cost targets.
Lead compounding and twin-screw extrusion development from lab and pilot scale through initial runs at contract manufacturers and toll processors, including trial planning, process parameter definition, and troubleshooting.
Characterize materials using rheology, thermal analysis, and mechanical testing, and use results to guide formulation and process decisions.
Print and test new materials to evaluate printability and performance, and trace print issues to material or process causes.
Deliver the first product by defining specifications, test methods, and acceptance criteria, and confirming that the first article meets them.
Lead root-cause analysis and corrective action for development and early-production issues, distinguishing material, process, and application causes.
Partner with the Product Manager on launch handoff, including specifications, process windows, test data, and documentation, and incorporate customer and field feedback into material design.
Document processes, findings, and lessons learned so knowledge is shared across the team.