Extrusion Engineer

Surf Search; San Diego (CA); On-site; USD 110,000 - 140,000; Full time

Job summary

Surf Search is seeking an experienced Extrusion Engineer to support development, optimization, and manufacturing of polymer-based components for medical devices. This on-site role is based in Carlsbad and involves close collaboration with R&D, Operations, Quality, and Supply Chain.

You will lead extrusion process development, evaluate polymers, apply statistics, and validate equipment to ensure robust, compliant manufacturing.

Qualifications

• Bachelor's degree in a related engineering field.
• 5+ years of hands-on polymer extrusion experience.
• Experience with complex tubing or small-diameter components.
• Experience with polymer processing and extrusion equipment.
• Experience in regulated medical device manufacturing.
• Experience with process qualification and validation.
• Strong data analysis and statistical skills.
• Ability to troubleshoot equipment and processes.

Responsibilities

• Lead extrusion process development and qualification.
• Develop and optimize tubing and polymer components.
• Support complex tubing configurations (multi-lumen, reinforced, layered).
• Evaluate polymers and materials for processing.
• Apply statistics to characterize processes and improve capability.
• Lead equipment qualification and processing improvements.
• Collaborate with R&D, Manufacturing, Quality, and Supply Chain.

Skills

Polymer extrusion

Process optimization

Statistics / data analysis

Troubleshooting

Cross-functional collaboration

Education

Bachelor's degree in Materials/Plastics/Chemical/Mechanical Engineering or related

Tools

Extrusion equipment

Materials testing

Job description

We are seeking an experienced Extrusion Engineer to support the development, optimization, and manufacturing of polymer-based components used in medical devices. This role will have a strong hands-on focus across process development, new equipment implementation, product improvement, and manufacturing support.

The engineer will work closely with cross-functional teams including R&D, Operations, Quality, and Supply Chain to develop robust processes and improve the performance, consistency, and manufacturability of polymer components.

This position is fully on-site in Carlsbad.

Responsibilities of the Extrusion Engineer:

• Lead engineering activities related to the development, qualification, and ongoing improvement of polymer extrusion processes.
• Develop and optimize tubing and other polymer-based components based on product performance and functional requirements.
• Support development of complex tubing configurations, including multi-lumen, reinforced, layered, lined, and variable-durometer constructions.
• Evaluate polymers and material systems and determine appropriate processing approaches for new and existing products.
• Apply statistical methods and data analysis to characterize processes, identify sources of variation, and improve process capability.
• Develop and optimize extrusion processes, tooling, equipment settings, and material handling methods.
• Support forming and secondary processing operations associated with polymer components.
• Specify, evaluate, install, and qualify manufacturing equipment, tooling, fixtures, and related systems.
• Lead efforts to improve process stability, yield, throughput, and overall manufacturing efficiency.
• Troubleshoot manufacturing and process issues and implement corrective and preventive improvements.
• Partner with external suppliers and manufacturers on materials, tooling, processing capabilities, and component sourcing.
• Work effectively across R&D, Manufacturing, Quality, and Supply Chain to support new product introduction and sustaining activities.
• Participate in projects involving equipment procurement, fabrication, installation, process development, and validation.

Requirements of the Extrusion Engineer:

• Bachelor's degree in Materials Engineering, Plastics Engineering, Chemical Engineering, Mechanical Engineering, or a related technical discipline.
• 5+ years of hands-on experience with polymer extrusion, preferably involving complex tubing or small-diameter components.
• Strong understanding of polymer processing, material behavior, tooling, and extrusion equipment.
• Experience developing and scaling extrusion processes from development through manufacturing.
• Experience with a range of thermoplastic materials and polymer systems.
• Familiarity with reinforced, multi-layer, multi-lumen, lined, or multi-durometer tubing is highly desirable.
• Experience with process characterization, statistical analysis, and process capability improvement.
• Demonstrated ability to troubleshoot equipment and manufacturing processes.
• Prior experience working in a regulated manufacturing environment; medical device experience strongly preferred.
• Experience with process qualification, equipment validation, and manufacturing documentation.