Senior Manufacturing Process Development Engineer, Medical

Job Purpose

The Senior Manufacturing Process Development Engineer will establish and optimize reliable processes, working cross-functionally to deliver safe, efficient processes that meet quality, cost, capacity, and customer requirements within our Medical business unit. This role will work cross-functionally on NPI teams to support process development and help successfully sample and launch new products. This role will also be responsible for taking new products from post-print to finished product by developing and scaling robust post-processing operations. They will provide technical leadership for the Production Team, define process requirements, coordinate with suppliers, and implement tooling and equipment solutions for post-processing printed parts and components.

Key Responsibilities

• Define and support post-processing steps (e.g., machining, blasting, deburring, cleaning, heat treating) for new product; turn product designs and requirements into robust, scalable manufacturing processes. 
• Oversee the implementation of manufacturing processes by collaborating with in-house technicians and external suppliers. Coordinate machine setup and process validation while maintaining technical ownership. 
• Define functional requirements for tooling, fixturing, and post-processing equipment, including identifying opportunities for automation or capital investment to improve productivity. Partner with suppliers to deliver reliable solutions, and lead their implementation, testing, and validation. 
• Write and maintain detailed work instructions, standard operating procedures (SOPs), and process documentation to ensure repeatable and high-quality production. 
• Lead Installation Qualifications (IQ) for manufacturing equipment and support QC and Quality Engineering in Operational and Performance Qualifications (OQ/PQ). Help ensure all processes meet quality and regulatory requirements. 
• Engage in the NPI process as required to understand part requirements and contribute to design-for-manufacturability (DFM) decisions. Work closely with design, quality, and production teams to align on cost, capability, and scalability. 
• Collaborate with product and manufacturing teams to define takt time, throughput targets, and resource needs (equipment, labor, space) to support forecasted production volumes – including estimating manufacturing costs and time standards for new and existing products. 
• Work with the HSSE team to assess risks and ensure that new equipment and processes meet internal safety and ergonomic standards. 
• Drive process improvements aimed at scrap reduction and cost savings using root cause analysis, lean tools and data-driven decision making. 

Qualifications

• Bachelor’s degree in Mechanical, Manufacturing, or Industrial Engineering (or related field) 
• 5+ years of experience in manufacturing engineering, with a focus on post-processing methods (e.g., machining, blasting, fixturing) 
• Hands-on experience developing and scaling production processes 
• Proficiency in process qualification tools and methods (e.g., PFMEA, DOE, IQ/OQ/PQ) 
• Strong cross-functional collaboration skills, including working with suppliers, technicians, and internal engineering, quality, and production teams 
• Experience creating and maintaining process documentation (e.g., SOPs, work instructions, validation plans) 
• Knowledge of Lean Manufacturing, root cause analysis, and continuous improvement methods 

Preferred Qualifications

• Experience with metal additive manufacturing and transitioning printed parts to finished product 
• Familiarity with post-processing techniques, GD&T, and tooling design (hands-on or oversight) 
• Background in regulated or quality-controlled environments (e.g., medical device, aerospace) and experience qualifying equipment or automated processes 
• Exposure to ERP/MES systems, manufacturing data tools, and safety or ergonomic assessments 

VulcanForms offers a competitive salary and equity package. Actual compensation is based on factors such as the candidate's skills, qualifications, and experience. In addition, VulcanForms provides comprehensive benefits including medical, dental, vision, and life insurance; generous paid time off; and a 401(k) plan with company match. 

The annual base salary range for this position is $106,500 to $146,000.