Process Development Engineer in Billerica

Energy Jobline ZR; Billerica (MA); On-site; USD 110,000 - 150,000; Full time

Benefits offered by this job

Health, Vision & Dental

Parental leave

Unlimited PTO

Holidays

Job summary

Boston Materials seeks a Process Development Engineer to turn cutting-edge R&D into reliable, scalable manufacturing for advanced materials. You will partner with Engineering and Operations to translate processes into repeatable procedures, ensuring high safety and yield targets.

You will own process control, data analysis, and a proactive approach to problem solving, enabling rapid scale-up and robust production in a startup-like environment.

Qualifications

• Bachelor’s or Master’s degree in Chemical Engineering or Materials Science (or equivalent).
• Experience developing chemical processes, roll-to-roll systems, and continuous manufacturing workflows.
• Hands-on hazard analyses and engineering controls for safe operation of complex processes.
• Strong understanding of sensing tech and data acquisition for process monitoring and control.
• Commitment to 6S principles and organized work areas.
• Proven track record in continuous improvement and throughput gains.
• Ability to perform process FMEAs and assess risks with mitigations.
• Solid grounding in applied statistics (capability analysis, control charts, ANOVA, hypothesis testing).

Responsibilities

• Design and optimize novel chemical/materials processes for commercial production.
• Deliver Release-to-Manufacturing milestones and scale capacity across processes.
• Develop and execute DOEs to improve process fundamentals and stability.
• Perform root cause analysis and resolve assignable variation.
• Identify instrumentation and controls for process characterization and targets.
• Conceive new equipment designs or modifications with internal/external teams.
• Assist Operations with workflow improvements.
• Work with Quality to establish product quality metrics (form, fit, function).
• Lead process FMEA for new processes.
• Maintain high safety, organization, documentation standards.
• Implement 6S for production equipment/workstations.
• Thrive in a startup or small-company setting.

Skills

Chemical Eng

Materials Sci

Process Development

Hazard Analysis

Data Acquisition

6S Principles

Continuous Improvement

Process FMEA

Statistics

Education

Bachelor's or Master's in Chemical Engineering or Materials Science

Tools

Sensing technologies

Data acquisition systems

Job description

Job DescriptionJob Description Boston Materials produces advanced materials with enhanced energy transfer properties using its patented Z-axis Carbon Fiber technology. The Company's products solve critical performance bottlenecks in applications spanning thermal, electrical, and structural use cases. Its breakthrough Liquid Metal ZRT thermal interface material is designed to solve thermal chokepoints that are facing the next of AI and HPC silicon. For more information, visit https://www.bomaterials.com/ THE OPPORTUNITY A career-defining opportunity rarely offersall ofthe following: Direct connection to the mission. Gain a clear understanding of the business and see how your work directly shapes outcomes. With no unnecessary layers, silos, or bureaucracy, every team member contributes meaningfully to the company's success and has the responsibility to drive real impact. Growth beyond a single role. At Boston Materials, you are not defined by yourpast experienceor limited by a job description. Working alongside leading experts in the field, you will take on new challenges, broaden yourexpertise, develop new capabilities, and take ownership of projects that matter–while contributing to the broader success of the organization. Work on problems that matter. Help solve some of the most pressing challenges in the Advanced Semiconductor, AI Infrastructure, and Advanced Materials industries. Boston Materials offers a rare combination of purpose, autonomy, and impact. We invite you to join us.
The Role

Boston Materials’ New Product Introduction (NPI) team is looking for an experienced Process Development Engineer who can turncutting-edgeR&D into reliable, production-ready manufacturing. In this role,you’llwork closely with Engineering and Operations to translate new processes into clear, repeatable procedures that support our next of thermal interface materials.

You’ll own the details of process control and data analysis, implement rigorous monitoring to spot patterns, uncover root causes, and push systems to meet high safety, capacity, and yield targets. This work isn’tjust aboutmaintainingstability,it’ssolving hard problems, removing bottlenecks, and unlocking the keys to scaling production processes to high-volume operations.

If you’redriven by troubleshooting complex systems,validatingbold ideas, and building processes that stand up to real-world production, this is the place to do it.

Your Responsibilities

• Designand optimize novel chemical/materials processes for commercial production of advanced materials.
• Deliver key Release-to-Manufacturing milestones and capacity scaling across new manufacturing and quality processes.
• Develop and execute DOE’s that improve understanding of process fundamentals and ultimately lead to increases in process stability, capability, and scale.
• Perform root cause analysis and resolution of assignable cause variation.
• Identify, select, and implement instrumentation, controls, etc. to enable process and material characterization necessary to achieve developmental goals.
• Conceive new process equipment designs or modifications to commercially available equipment to suit process requirements. Lead activities of external vendors or internal counterparts to execute these designs/modifications.
• Assist Operations team in devising and implementing workflow improvements.
• Work with quality engineers to establish quality metrics that assure product form, fit, and function.
• Lead process FMEA for new processes.
• Conspicuously exemplify high standards of safety, organization, communication, and documentation.
• Implement 6S for production equipment and workstations.
• Work effectively in a startup or small company setting. Embrace challenges, adapt to changes, and continuously seek to improve.

Your Skills and Expertise

• Bachelor's or Master’s degree in Chemical Engineering or Materials Science strongly ; equivalent experience considered.
• Demonstrated success developing chemical processes, roll-to-roll systems, and other continuous manufacturing workflows.
• Hands-on ability to perform hazard analyses, define engineering controls, and ensure safe operation of complex processes.
• Strong understanding of sensing technologies and data acquisition methods for process monitoring and control.
• Commitment to 6S principles and building clean, organized, and efficient work areas.
• Consistent track record of driving continuous improvement initiatives that raise throughput, quality, and reliability.
• Ability to perform process FMEAs to identify risks, prioritize mitigations, and strengthen process robustness.
• Solid grounding in applied statistics, including capability analysis, control charts, ANOVA, and hypothesis testing.

Summary of Benefits

• Health, Vision & Dental – Boston Materials pays 75% of Health, Vision and Dental Care coverage for employee and dependents
• 4 weeks of supplemental Paid Parental and Family Leave
• Unlimited Paid Time Off
• Holidays: 14 days/year

Boston Materials is an EOE and at the forefront of materials innovation, the key to which is diverse teams with unique backgrounds and experiences. We are committed to employing a diverse workforce with equal employment opportunities regardless of , , , , , , , , expression, marital status, veteran status, or . Applicants must be currently authorized to work in the US on a full-time basis.