Sr Staff Process Development Engineer
About The Position
Dexcom Corporation (NASDAQ DXCM) is a global leader in continuous glucose monitoring (CGM), aiming to revolutionize healthcare by empowering people to take control of their health. This role is within Dexcom’s Product Development organization, focusing on advancing continuous glucose monitoring technology through innovation in materials, process engineering, and device design. The Senior Staff Process Engineer will bridge early concept development with scalable, high-volume manufacturing, driving advances in precision materials processing and embedding Product & Process Excellence principles into development. The position involves leading process technology development strategies for next-generation products, aligning product requirements with process capabilities, and influencing product design through DFx insights. The engineer will develop and scale advanced processes for micro-dispensing, bonding, and encapsulation, architect and execute process characterization strategies, and define critical process parameters (CPPs) and critical quality attributes (CQAs). The role ensures processes are designed for scalability and manufacturability, leads design verification readiness, establishes metrology and inspection strategies, and collaborates cross-functionally with R&D, quality, reliability, and manufacturing.
Requirements
- Deep expertise in adhesives, epoxies, soft materials, or other precision material systems used in high-performance devices.
- Strong experience in design realization and process-driven product development within R&D environments.
- Advanced proficiency in DOE, process capability analysis, and statistical modeling.
- Track record of developing scalable, high-precision processes for complex product architectures.
- Application of Product & Process Excellence principles (Lean, Six Sigma, CPM) to drive process capability, variation reduction, and manufacturability.
- Strong knowledge of process-material interactions and their impact on performance and reliability.
- Effective influence on cross-functional teams and mentorship of engineers in process characterization and technical rigor.
- Clear communication of complex technical concepts and ability to drive alignment across engineering disciplines.
- Typically requires a Bachelor’s degree in a technical discipline, and a minimum of 13+ years related experience or a Master’s degree and 8+ years equivalent industry experience of a PhD and 5+ years of experience.
Nice To Haves
- Experience in industries such as semiconductor, advanced packaging, displays, or high-resolution wearable devices.
Responsibilities
- Lead process technology development strategies that enable next-generation product architectures, including smaller form factors and tighter tolerances.
- Drive design realization by aligning product requirements with process capability and manufacturing strategy.
- Influence product design through DFx (DFM, DFA, DFR) insights, leveraging deep process understanding and trade-off analysis.
- Develop and scale advanced processes for micro-dispensing, bonding, and encapsulation of adhesives, epoxies, and soft materials.
- Architect and execute process characterization strategies, including DOE, multivariate analysis, and statistically rigorous experimentation.
- Define and manage CPPs, CQAs, process windows, and control strategies using Product & Process Excellence methodologies.
- Ensure processes are designed for scalability, robustness, and high-volume manufacturability early in development.
- Lead design verification (DV) readiness, including process definition, risk mitigation, and capability demonstration.
- Establish metrology and inspection strategies aligned to micro-scale feature requirements and tolerance validation.
- Lead cross-functional collaboration across R&D, quality, reliability, and manufacturing, serving as a key technical voice in design reviews.
Benefits
- A front row seat to life changing CGM technology.
- Learn about our brave #dexcomwarriors community.
- A full and comprehensive benefits program.
- Growth opportunities on a global scale.
- Access to career development through in-house learning programs and/or qualified tuition reimbursement.
- An exciting and innovative, industry-leading organization committed to our employees, customers, and the communities we serve.
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What This Job Offers
Job Type
Full-time
Career Level
Senior
