Senior Process Engineer- Materials/Metallurgy

Stryker•Mahwah, NJ

6d•Onsite

About The Position

We are seeking a Senior Materials Science Engineer to lead the development, industrialization, and scale-up of Low Pressure Metal Injection Molding (LPMIM) technologies within Advanced Operations & Manufacturing. This role plays a critical part in enabling next-generation medical device products — translating materials science innovation into scalable, high-volume, cost-optimized, and compliant manufacturing solutions. You will serve as the technical authority for LPMIM materials and processes, driving performance, reliability, and manufacturability from early concept through commercial production. This is a high-visibility role partnering closely with R&D, Design Engineering, Global Manufacturing, Quality, and external suppliers to build differentiated manufacturing capability.

Requirements

Bachelor’s degree in Materials Science, Metallurgy, or related field.
2+ years of experience in Metal Injection Molding (MIM), powder metallurgy, thermally processed metals manufacturing or related duties.

Nice To Haves

Master’s degree in Materials Science or related discipline.
Demonstrated success scaling processes from prototype to high-volume production.
Experience in medical device or other regulated, high-precision industries.
Strong expertise in MIM materials science, sintering behavior, tooling principles, and feedstock design.
Proficiency in CAD (SolidWorks or Creo) and simulation tools (mold flow, thermal analysis).
Experience with validation protocols, DOE, SPC, and structured problem-solving methodologies.
Six Sigma Green or Black Belt certification.
Working knowledge of GD&T (ASME Y14.5).

Responsibilities

New Product Introduction (NPI) & Design Enablement Partner with R&D and Design Engineering to evaluate LPMIM feasibility for new components and assemblies.
Lead Design for Manufacturability (DFM/DFA) reviews, translating product requirements into material, geometry, and process parameters.
Define material selection strategies, feedstock composition, and downstream processing requirements to meet performance and regulatory standards.
Materials & Process Development Develop and optimize LPMIM feedstocks, molding parameters, debinding profiles, and sintering cycles to achieve mechanical, chemical, and dimensional targets.
Conduct advanced materials characterization (SEM, metallography, DSC/TGA, mechanical testing) to validate process capability and long-term reliability.
Lead structured root cause investigations and implement sustainable corrective and preventive actions.
Manufacturing Scale-Up & Integration Design and scale robust LPMIM processes for high-volume, cost-efficient production.
Develop capacity models, cycle time analyses, and network-level scaling strategies.
Integrate molding, debinding, sintering, and material handling systems into full production cells in partnership with global sites and suppliers.
Tooling & Equipment Leadership Lead mold and tooling strategy for high-volume LPMIM operations, focusing on thermal behavior, wear performance, and repeatability.
Partner with suppliers through design, fabrication, FAT/SAT, and lifecycle management of tooling and capital equipment.
Validation, Compliance & Quality Systems Lead process validation activities (IQ/OQ/PQ) in compliance with FDA, ISO 13485, and internal quality systems.
Drive PFMEA and risk mitigation strategies for material and process-related risks.
Technical Leadership & Continuous Improvement Serve as the LPMIM subject matter expert across Advanced Operations, influencing technical decisions throughout the product lifecycle.
Support pilot builds, engineering runs, and production ramp-up at global manufacturing sites.
Champion Lean and Six Sigma initiatives to improve yield, reduce scrap, and optimize material cost.
Identify and deploy emerging materials and technologies to advance LPMIM capability.