Staff Design & Additive Manufacturing Engineer, Spine R&D – DePuy Synthes

Johnson & Johnson Innovative Medicine • Raynham, MA

1d • Hybrid

About The Position

This position is a dual role, with half of the time spent on Product Design within the Spine Surgeon Request Team and the other half supporting the development and optimization of Additive Manufacturing processes and products for R&D. The role owns the additive manufacturing loop—from build file creation and printer operation through part removal, inspection, and structured feedback into subsequent design iterations. This position is best suited for an engineer who is comfortable operating metal AM equipment, applying DfAM principles, and working within a regulated medical device development environment. A key focus of the position is expanding the team’s AM capabilities, and the Staff Engineer will collaborate closely with cross‑functional teams—including Manufacturing Innovation, Quality, Validation, Maintenance, and Calibration. The role involves developing and supporting value‑stream projects, ensuring alignment, standardization, and best‑practice implementation across the network.

Requirements

• Bachelor’s degree or equivalent experience in Engineering (or equivalent).
• 5+ years of Product Development with experience developing CAD models and detailed engineering drawings, preferably using Siemens NX.
• 3+ years of hands-on experience with metal additive manufacturing, preferably LPBF.
• Demonstrated ability in additive manufacturing/process engineering.
• Demonstrated experience creating metal AM build files (supports, orientation, slicing, layout).
• Experience with industrial LPBF printers, from setup to completed build, to part removal and basic post-processing techniques.
• Strong experience in structured problem solving and root cause analysis.
• Excellent technical content skills (specifications, validation protocols, change control).

Nice To Haves

• Proven experience supporting NPI, scale‑up and transfer activities.
• Experience leading multi-functional teams and influencing collaborators at multiple levels.
• Experience specifically with titanium spinal implants or orthopaedic medical devices.
• Familiarity with LPBF platforms, 3DS preferred (e.g., EOS, SLM Solutions, Renishaw, Concept Laser).
• Experience with build prep software such as Materialise Magics, EOSPRINT, Netfabb, nTopology, or similar.
• Exposure to post-processing steps commonly used in medical devices (heat treatment, HIP, surface finishing).
• Familiarity with calibration, maintenance practices and working closely with in‑house maintenance teams.
• Knowledge of regulatory requirements and submissions applicable to medical device manufacturing.
• Prior experience mentoring/leading emerging engineers or small technical teams.

Responsibilities

• Lead and contribute to the design and development of innovative medical devices and technologies supporting new custom product development and specialty product lifecycle management.
• Develop CAD models and detailed engineering drawings in accordance with company standards, including GD&T and tolerance analysis.
• Perform engineering analyses and simulations to validate design concepts and optimize performance.
• Lead or participate in cross-functional project teams as needed, and deliver technical solutions aligned with clinical (direct surgeon requests), regulatory, quality, and business objectives.
• Support design control activities and the transfer of designs from concept through prototype to production.
• Lead end‑to‑end process development and industrialization for complex processes and New Product Introductions (NPI), ensuring scalable, robust, and validated manufacturing processes.
• Create, modify, and optimize LPBF build files for titanium medical implants (e.g., Ti 6Al 4V), including: Part orientation and nesting strategy, Support generation and optimization to balance surface quality and removability, Thermal management considerations for distortion-sensitive implant geometries.
• Review CAD models for printability, manufacturability, and risk, providing DfAM feedback tailored to spine implants (e.g., lattice regions, fixation features, anatomical surfaces).
• Maintain build documentation consistent with R&D and design control expectations.
• Own the end-to-end operation of industrial LPBF metal printers, including: Machine setup, calibration, and pre-build checks, Titanium powder handling, recycling, and traceability, Build execution, monitoring, and first-level troubleshooting, Identify print anomalies relevant to implant manufacturing (distortion, support failure, surface defects).
• Execute post-build workflows including: Depowdering and controlled powder recovery, Build plate removal and part separation, Support removal with attention to implant-critical surfaces.
• Perform preliminary inspection and documentation: Visual inspection and defect classification, Basic dimensional verification, Identification of risks impacting downstream testing (mechanical, fatigue, coating, etc.).
• Provide clear, structured feedback from each build to inform: Design revisions, Build orientation and support changes, Parameter and layout refinements.
• Partner closely with Spine R&D engineers, Designers, and manufacturing teams to accelerate prototype learning cycles.
• Support continuous improvement of AM processes, SOPs, and internal best practices for medical titanium printing.
• Support cost reduction and productivity initiatives (scrap/rework reduction, throughput improvements, consumables optimization) with measurable savings and sustainability impacts.
• Provide technical mentorship to engineers and technicians, champion continuous improvement culture, and support capability development across the organization.

Benefits

• Vacation –120 hours per calendar year
• Sick time - 40 hours per calendar year; for employees who reside in the State of Colorado –48 hours per calendar year; for employees who reside in the State of Washington –56 hours per calendar year
• Holiday pay, including Floating Holidays –13 days per calendar year
• Work, Personal and Family Time - up to 40 hours per calendar year
• Parental Leave – 480 hours within one year of the birth/adoption/foster care of a child
• Bereavement Leave – 240 hours for an immediate family member: 40 hours for an extended family member per calendar year
• Caregiver Leave – 80 hours in a 52-week rolling period10 days
• Volunteer Leave – 32 hours per calendar year
• Military Spouse Time-Off – 80 hours per calendar year

What This Job Offers

• Job Type: Full-time
• Career Level: Senior
• Number of Employees: 5,001-10,000 employees