Sr. 3D Process Engineer

Job DescriptionJob DescriptionDescriptionAlign Technology’s 3D Printing Process team is seeking a Sr. 3D Process Engineer to join our San Jose, CA location. This in-person role involves hands-on, in-lab research and development focused on advancing additive manufacturing process control. The successful candidate will lead targeted R&D initiatives to solve fundamental process problems, serve as a subject matter expert in additive manufacturing, and collaborate with cross-functional teams to support regulatory submissions, process validation, and technology transfer activities.
Role expectations

• Independently operate new additive manufacturing equipment and post processing equipment.
• Perform material and product testing using standard and non-standard material testing equipment.
• Collect, maintain and organize data in accordance to internal standards and quality requirements. 
• Participate, and lead select weekly and bi-weekly technical meetings with cross functional groups 
• Present data, findings, and ideas to the process and cross-functional teams on a weekly basis
• Use statistical tools to analyze, interpret, and present experiment results. 
• Be responsible for writing, maintaining, and transferring work instructions to manufacturing teams. 
• Be responsible for writing, maintaining and supporting protocols for process and equipment qualifications and process transfer. 
• Be responsible for writing work instructions for core Process R&D activities. 
• Work closely with cross functional collaborators to support and to receive support on major project milestones. 
• Serve as SME for design for additive manufacturing (DFAM) to support printing and post process development. 
• Operate, collect and analyze data from polymer characterization equipment to support fundamental research in the area process-structure-property explorations.
• Apply your expertise in process-structure-property relationship exploration to study, and tune process to match desired performance and accuracy metrics. 
• Use and develop methods to collect, process and analyze data from advanced metrology techniques like CT, CMM and similar equipment
• Be responsible for collection, processing and analysis of orthodontic performance data for exploring the relationship between process and performance. 
• Collaborate with the manager to identify, plan, and assemble core team to support independent R&D topics.  Independently design, setup and execute experiments to study process-structure-property relationships for polymer AM systems for the purpose of understanding/optimizing the manufacturing process.
• Lead and delegate tasks to Jr. team members and technicians supporting the R&D activities. 
• Create, evaluate, support prototyping of equipment, jigs, fixture and tools necessary for manufacturing process internally or with external support.
• Maintain vendor relationships and be responsible for design review and release of custom equipment. 
• Study and develop metrics to explore the process capability of end-to-end pilot manufacturing process for R&D products. 
• Serve as lead for development of acceptance metrics, process performance criterion, and in-process monitoring criterion.
• Lead activities related to test method development and validation.  
• Lead and support the planning, execution and documentation of experiment results and analysis for regulatory submissions. 
• Serve as SME for internal and external audits related to process development and optimization. 
• Provide the requirements for manufacturing software such as support , slicing, layout etc.
• Serve as a technical liaison for manufacturing software development, prototyping (coding, code editing), and testing plan. 
• Support and participate in calibration, spirit committee, and safety programs. 
• Foster collaboration with cross functional teams, support onboarding of Jr. engineers.  
• Work in a fast-paced environment and meet critical deadlines
• Problem solve issues with attention to detail
• Actively coach, motivate, mentor and provide leadership to peers and Jr. engineers

What we're looking for

• MS degree in mechanical or Biomedical Engineering (other scientific disciplines considered) with 6-8 years of direct 3D printing experience related to SLA/ Resin based 3D printing machines, or printed medical devices. 
• PhD degree in mechanical or relevant interdisciplinary degree with 3-5 years of direct focus on process or post process development for photopolymer based additive manufacturing systems. Experience with AM systems for medical device applications is a bonus. 
• Demonstrable expertise in statistical analysis and design of experiments
• Demonstrable expertise in leading independent research and troubleshooting problems with logical approach.
•  Experience with handling and working with chemicals such as Iso propyl alcohol, photopolymers, cleaning agents. 
• Experience being comfortable with taking risk-based decisions for ambiguous problem statements. 
• Excellent technical communication skills (technical writing and presentation skills)
• Strong mathematical ability to support physical process modelling using experiment observations and results.  
• Experience using instruments such as CT scanners, Surface profilers, Digital microscopes and similar imaging techniques. 
• Demonstrable experience in collaboration with multidisciplinary teams  

Nice to Have:

• Practical coding experience in python or equivalent . 
• Experience with end-to-end development of printing or post process parameters for a specific application or material. 
• Experience working in a collaborative environment with polymer design/engineering groups.
• Experience in development of metrics for process control and process capability. 
• Experience using AM tools such as solidworks, slicer and other toolpath SW.
• Experience with building/operating custom 3D printers, material testing, or post processing equipment.
• Experience with 3D printed devices for medical or biomechanical applications 

Pay TransparencyIf provided, base salary or wage rate ranges are the range in which Align reasonably expects to set a candidate’s pay for the posted position. Actual placement depends on the individual skills and experience level of a candidate plus the total compensation and equity across team members. For other locations outside of the primary location, the base salary range will be adjusted geographically.  For Field Sales roles, the salary listed is the base pay only and does not include the applicable incentive compensation plan. A cost of living adjustment may be added to base pay for higher cost areas in the U.S.  Our hourly rates are a standard pay determined based on the position and your location, year in school, degree, and experience.