Lead Process Engineer - Poly6

JOB DESCRIPTION: Lead Process Engineer  

Burlington, MA, USA 

Poly6, an emerging leader in aerospace and defense innovation, is enabling production of complex turbine engine designs by combining additive manufacturing, advanced computation and material science. Our technology is uniquely suited to increase the efficiency of complex manufacturing processes as well as advance engineering design capabilities. Long term benefits of Poly6’s products include reduced greenhouse gas emissions for the aviation sector. You will have the opportunity to work alongside a highly talented team to solve problems in one of the world’s most complex engineering sectors: aviation. 

JOB SUMMARY 

Reporting to the Plant Engineering Manager, the Lead Process Engineer - Additive Manufacturing will be primarily focused on the process control and technical execution of additive manufacturing processes within the manufacturing facility in Burlington, MA, and secondarily to assist with technology transfer to a scaled greenfield manufacturing facility in Ohio. This position requires a strong working knowledge of process control, manufacturing, materials science, with strong investigational and root cause analysis skills. Specific job-related responsibilities include: 

RESPONSIBILITIES 

• Lead the control and optimization of manufacturing processes, focusing on stability, statistical process control (SPC), and effective change management during scale-up. 

• Maintain and analyze process parameters, connecting process inputs to product outputs to optimize control limits and enhance overall product quality. 

• Understand and optimize material interactions with manufacturing processes to improve product performance and reliability. 

• Measure and control Key Process Variables (KPVs), diagnosing and monitoring out-of-control events to ensure stable and predictable operations. 

• Contribute to cross-functional projects aimed at process control, scrap reduction, and continuous improvement. 

• Support root cause analyses for process non-compliances and ensure timely corrective actions. 

• Help maintain robust process documentation, identifying and implementing opportunities for workflow improvements. 

• Provide hands-on technical assistance, including repairing, improving, installing, maintaining, and validating manufacturing equipment. 

• Collaborate cross-functionally on continuous improvement initiatives related to equipment implementation, cost reduction, and productivity enhancements. 

• Support product engineering efforts by providing process analysis, data reporting, and recommendations. 

• Standardize preventative maintenance systems and documentation for manufacturing equipment, ensuring adequate training for seamless handoff to operational counterparts. 

• Offer rapid-response daily production support, including personnel training, data/scrap analyses, troubleshooting process problems, and performing equipment maintenance. 

• Support Design of Experiments (DOEs) and trial execution to validate process improvements and changes, including participation in PFMEA and JSA initiatives as needed. 

• Participate in special projects as assigned by management. 

QUALIFICATIONS 

• Bachelor’s degree in Engineering (or related field) with 2-4 years of relevant experience, or 4+ years of equivalent experience in a manufacturing environment. 

• Demonstrated experience in controlled manufacturing environments focusing on process control, process improvement, and operational excellence. 

• Proficiency in applying SPC and DOE methodologies for process analysis and improvement. 

• Working knowledge of statistical analysis software (e.g., Minitab, JMP) and advanced Microsoft Excel skills. 

• At least 1 year of practical experience applying Six Sigma principles in manufacturing, with documented project successes. 

• Hands-on experience with manufacturing equipment, processes, and related software tools. 

PREFERRED EXPERIENCE 

• Experience with polymer or similar material applications in industrial manufacturing. 

• Strong skills with the Microsoft Office suite. 

• Excellent verbal and written communication abilities, with a track record of working effectively across engineering and operations teams. 

• Hands-on experience operating, maintaining, and optimizing production processes, including familiarity with CAD models and related tools. 

• Understanding of processes, systems, and technical aspects of scaled manufacturing operations. 

• A data-driven mindset focused on driving innovation and improving process capability and efficiency. 

• Six Sigma Green Belt or equivalent certification. 

• Experience with control plans and data collection systems for process monitoring and reporting. 

• Involvement in new process development and scale-up activities. 

• Understanding of material interactions within manufacturing processes and the ability to optimize for improved performance. 

This position requires access to information protected under U.S. export control laws, including the International Traffic in Arms Regulations and/or the Export Administration Regulations. Please note that any offer for employment may be conditioned on authorization to receive software or technology controlled under these U.S. export laws without sponsorship for an export license. Poly6 is an equal opportunity employer. We do not discriminate based on age, color, genetic information, religion, sex, veteran status, or national origin.