Materials Engineer

Ellaway Blues Consulting; Town of Texas (WI); On-site; USD 90,000 - 130,000; Full time

Job summary

Ellaway Blues Consulting seeks a Process Development Engineer to join our client's advanced manufacturing and product engineering team in the Dallas–Fort Worth metro area.

The role focuses on developing and optimizing manufacturing processes that support research and commercial-scale production through experimental design, materials characterization, pilot-scale manufacturing, and data-driven problem solving.

Qualifications

• Bachelor's or Master's degree in Materials Science & Engineering, Metallurgy, Mechanical Engineering, or related.
• Experience with pilot-scale manufacturing, casting, powder processing, sintering, and materials characterization (SEM/XRD) and experimental design.

Responsibilities

• Design and execute experimental programs to develop and optimize advanced manufacturing processes for high-performance engineered materials.
• Develop, evaluate, and improve pilot-scale production methods and transition them into commercial operations.
• Use materials characterization techniques and analytical testing to identify improvements, troubleshoot challenges, and enhance product performance.
• Analyze data, prepare technical reports, and develop SOPs to support process development and continuous improvement.
• Collaborate with Manufacturing, Process Engineering, Quality, R&D, and EHS teams to improve process capability and support new product commercialization.

Skills

Process development

Data analysis

Experiment design

Team collaboration

Problem solving

Education

Bachelor's or Master's in Materials Science & Engineering / related technical field

Tools

Python

MATLAB

SEM

XRD

DOE / statistics

Job description

We are seeking a Process Development Engineer to join our client's advanced manufacturing and product engineering team in the Dallas–Fort Worth metro area. Our client is a well-established industrial manufacturer at the forefront of advanced materials, precision manufacturing, and next-generation production technologies. The organization is experiencing significant growth and expanding its domestic manufacturing capabilities through continued investment in innovative materials processing and advanced production systems.

This is a highly technical, hands-on role focused on developing and optimizing manufacturing processes that support both research initiatives and commercial-scale production. The ideal candidate enjoys working in a collaborative environment that combines experimental process development, materials characterization, pilot-scale manufacturing, and data-driven problem solving to bring innovative technologies from concept to full-scale production.

Key Responsibilities:

• Design and execute experimental programs to develop and optimize advanced manufacturing processes for high-performance engineered materials.
• Develop, evaluate, and improve pilot-scale production methods, collaborating with manufacturing teams to successfully transition new processes into commercial operations.
• Utilize materials characterization techniques and analytical testing to identify process improvements, troubleshoot manufacturing challenges, and enhance product performance.
• Analyze experimental data, prepare technical reports, and develop standard operating procedures to support process development, knowledge sharing, and continuous improvement initiatives.
• Partner closely with Manufacturing, Process Engineering, Quality, R&D, and EHS teams to improve process capability, support new product commercialization, and maintain world-class safety and operational standards.

The ideal candidate will hold a Bachelor's or Master's degree in Materials Science & Engineering, Metallurgy, Mechanical Engineering, or a related technical discipline. They will have experience in process development, materials processing, or manufacturing within metals, ceramics, or other advanced material systems. Experience with pilot-scale manufacturing, casting, powder processing, sintering, materials characterization techniques such as SEM or XRD, experimental design, statistical analysis, Python or MATLAB, and process optimization is highly desirable.

This is a high-impact opportunity within a rapidly growing organization offering exceptional career development and the chance to help advance innovative manufacturing technologies in the United States. It is an outstanding opportunity for a technically driven engineer who thrives in a hands-on, collaborative environment and is passionate about developing advanced manufacturing processes that enable the next generation of industrial innovation.