Sr. Application Engineer

Tegra Medical Holdings•Franklin, MA

13h•Onsite

About The Position

The Senior Application Engineer is a strategic technical leader responsible for evaluating and defining the cost structure of new and legacy medical device manufacturing projects. The role combines technical expertise with cross-functional leadership to establish manufacturing sequences, assess feasibility and required internal or external technologies, and provide recommendations that guide product introduction and scaling. As a technical advisor, the Senior Application Engineer provides Design for Manufacturability (DFM) guidance, leads cost modeling, and connects customers with engineering, sales, and production teams from early quoting through full-scale manufacturing. The position is onsite at the assigned company location and supports technical and financial alignment across the organization.

Requirements

At least 8 years in manufacturing, processing, applications engineering, or cost estimating; medical device or precision manufacturing experience is preferred.
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

Medical device or precision manufacturing experience.
SolidWorks/CAD experience.
Advanced training or certifications in cost estimating, lean manufacturing, or DFM/A.

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 covering feasibility, validation, risk, tooling, capital, and ROI; recommend whether to develop capabilities internally, source externally, or exclude them.
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 delivered on schedule.
Support handoff of awarded projects to development and production, ensuring assumptions, cost targets, risks, and commitments are owned by receiving teams.
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.