Senior Materials Engineer, Thermoplastics and Compounding

Lyten; San Jose (CA); On-site; USD 117,000 - 175,000; Full time

Job summary

Lyten is leading an industrial revolution with Lyten 3D Graphene™ and advanced thermoplastic compounds. The role focuses on upstream product development: designing materials, compounding, testing, and delivering first products ready for launch.

You’ll work between materials science, manufacturing, and the customer, diagnosing root causes and driving solutions without requiring prior additive manufacturing experience.

Qualifications

• BS with 5+ years experience, MS with 3+ years, or PhD in Polymer Science/Polymer/Chemical Engineering/Materials Science
• Working knowledge of polymer structure–property relationships and polymer rheology
• Hands-on experience with thermoplastic compounding and melt processing, particularly twin screw extrusion
• Demonstrated engineering problem-solving: DOE, failure analysis, process characterization
• Experience with fillers/additives in thermoplastics (e.g., graphene) and data interpretation from characterization methods
• Ability to run and interpret 3D print tests (FFF/FDM)
• Willingness to travel ~10% and communicate with suppliers/internal teams
• Clear written and verbal communication with suppliers and internal teams

Responsibilities

• Design and develop thermoplastic and filament formulations to meet performance and cost targets
• Lead compounding and extrusion development from lab to first runs at manufacturers
• Characterize materials using rheology, thermal analysis, and mechanical testing
• Print with and test new materials to evaluate printability and performance
• Define specifications, test methods, and acceptance criteria for first article
• Drive root cause analysis on development and early production issues
• Partner with Product Manager on a clean handoff to launch with data and documentation
• Document processes and lessons learned for team-wide knowledge sharing

Skills

Polymer science

Rheology

Twin screw extrusion

Material characterization

3D printing (FFF/FDM)

Problem solving

Supplier communication

Education

Bachelor's degree in polymer science/engineering

Master's degree in polymer science/engineering

PhD in polymer science/engineering or Materials science

Tools

Twin screw extrusion

Melt processing

Rheometer

Thermal analysis equipment

3D printing (FFF/FDM)

Job description

Lyten is leading an industrial revolution through Lyten 3D Graphene™, a breakthrough supermaterial unlocking a new generation of products — from lithium–sulfur batteries and energy storage systems to concrete admixtures, lightweight composites, and next‑generation sensors that are revolutionizing industries. Together, these innovations are making a massive global improvement and driving real‑world impact across energy, mobility, construction, and defense.

At Lyten, we believe the most meaningful careers begin with purpose — and with people who want to make a difference. We’re not just developing advanced supermaterials — we’re about to change the world as we know it, reshaping how energy is stored, how products are built, and how progress is made.

We’re entering an exciting growth phase, scaling production across the U.S. and Europe and expanding our team of engineers, scientists, and innovators.

We develop and commercialize advanced thermoplastic compounds and 3D printing filaments. This role owns the upstream half of product development: you’ll design materials, compound them, test them, print with them, and deliver a first product that is ready to hand off for launch. You’ll work hand in hand with the Product Manager, who carries each product through launch and commercial support, and you’ll stay accountable for how your materials perform when they are printed and used. The work sits between materials science, manufacturing, and the customer. A strong candidate understands polymer processing well enough to diagnose a compounding, printing, or performance issue, trace it to its root cause (the material, the process, or the application), and fix it. We want someone who sees a problem and moves toward a solution, and who is motivated by shipping reliable products rather than by open‑ended research. You don’t need prior additive manufacturing experience. You need the compounding and processing depth, and the engineering problem‑solving discipline, to do the job here.

What You’ll Do

• Design and develop thermoplastic and filament formulations, including selection of resins, fillers, and additives, to meet performance, processability, and cost targets
• Lead compounding and twin screw extrusion development, from lab and pilot scale through first runs at contract manufacturers and toll processors, including trial planning, process parameter definition, and troubleshooting
• Characterize materials using rheology, thermal analysis, and mechanical testing, and use the data to guide formulation and process decisions
• Print with and test new materials to evaluate printability and performance, and trace print issues back to the material or the process
• Deliver the first product: define specifications, test methods, and acceptance criteria, and confirm the first article meets them
• Drive root cause analysis and corrective action on development and early production issues, distinguishing material, process, and application causes
• Partner with the Product Manager on a clean handoff to launch, including specifications, process windows, test data, and documentation, and to bring customer and field feedback into material design
• Document processes, findings, and lessons learned so that knowledge is shared across the team

Required Qualifications

• BS with 5+ years of experience, or MS with 3+ years of experience, or PhD in Polymer Science, Polymer/Chemical Engineering, Materials Science, or a related field
• Working knowledge of polymer structure‑to‑property relationships and polymer rheology, and the ability to apply it to real production and development problems
• Hands‑on experience with thermoplastic compounding and melt processing, particularly twin screw extrusion, in a production or scale‑up setting
• Demonstrated engineering problem‑solving: a structured approach to root cause analysis (for example DOE, failure analysis, process characterization) and a record of driving issues to resolution
• Experience with fillers and additives in thermoplastics, such as glass fiber, carbon fiber, carbon nanotubes, or graphene, including dispersion and the effect on processing and properties
• Familiarity with polymer characterization methods, including rheology, thermal analysis, and mechanical testing, and the ability to interpret data and act on it
• Ability to run and interpret 3D print tests, with familiarity with FFF/FDM printing
• Comfortable working on a production floor and traveling to supplier sites, roughly 10 percent
• Clear written and verbal communication with suppliers, internal teams

Nice to Have

• In‑depth experience with 3D printing or additive manufacturing, particularly FFF/FDM filament
• Experience with filament extrusion, including diameter control and spooling
• Familiarity with engineering thermoplastics such as PA, PC, PEEK, or PEI
• Experience taking thermoplastic products from development through manufacturing
• Customer‑facing or applications engineering experience
• Working knowledge of ASTM/ISO polymer test standards
• Experience working with contract manufacturers, including audits and corrective action processes
• Ability to make and defend technical trade‑off decisions involving cost, quality, and schedule

Compensations Range

The expected base salary range for this position is between

$116,600.00 - $175,000.00

The level of pay within the range will depend on a variety of job‑related factors that may include location, relevant prior experience and/or education, or particular skills and expertise.

Disclosures

This compensation and benefits information is based on Lyten’s estimate as of the date of publication and may be modified in the future. We generally do not negotiate on salary once we have made an offer. The level of pay within the range will depend on a variety of job‑related factors that may include location, relevant prior experience and/or education, or particular skills and expertise. New hires joining the company tend to be paid within the starting base pay range noted above, with opportunities to increase pay over time based on development of additional skills, competencies, and company‑specific knowledge.

In addition to base pay this position is eligible for tier based bonus and equity, healthcare, dental, vision, corporate discounts, paid holidays, PTO and sick time, 401K, employee relocation plan (if applicable).

Export/ITAR Compliance Disclosure

Certain positions within Lyten, Inc. require compliance with export control laws and, as a result, all interviewed candidates will be screened pre‑interview to determine their eligibility in light of export restrictions.

This position requires access to technology, software and other information that is subject to governmental access control restrictions, due to export controls. Employment in this position is conditioned on the continued availability of government authorization to authorize release of such items, to the extent required, including without limitation an export license, or other documentation required to establish authorization to receive access to such items. Company may delay commencement of employment, rescind an offer of employment, terminate employment, and/or may modify job responsibilities, compensation, benefits, and/or access to Company facilities and information systems, as Company deems appropriate, in order to ensure compliance with applicable government access control restrictions.

Lyten is an equal opportunity employer

All qualified applicants will receive consideration for employment without regard to race, religion, color, national origin, sex, age, status as a protected veteran, or status as a qualified individual with a disability. EEO Employer/Vet/Disabled.

Why Work at Lyten

At Lyten, you’ll be part of a team that’s redefining what’s possible in energy, materials, and manufacturing. We’re not just imagining the future — we’re building it today with breakthrough technologies that are changing how products are made and how industries innovate.

Our people are the heart of that mission. From world‑class scientists and engineers to creative problem‑solvers in operations, manufacturing, and commercialization, every member of the Lyten team plays a role in turning bold ideas into real‑world impact. We believe that the best work happens when you’re doing great things in the world — with people you like. Collaboration, curiosity, and a shared sense of purpose drive everything we do.

• A mission that matters: Contribute directly to solving complex challenges in energy, mobility, and materials innovation.
• Cutting‑edge innovation: Work on technologies at the intersection of materials science, energy storage, and advanced manufacturing that strengthen energy security and local supply chains.
• Extraordinary people: Join a team of talented, friendly, and down‑to‑earth innovators who support, challenge, and inspire one another every day.
• Teamwork and culture: Experience a workplace built on trust, respect, and shared success — where collaboration fuels breakthroughs and everyone’s ideas are heard.
• Global impact: Help scale new materials and energy solutions that reinforce industrial resilience across the U.S. and Europe.
• Career growth: Be part of a fast‑moving company entering a commercial growth phase, with opportunities to lead, learn, and make your mark.
• Purpose‑driven values: Thrive in an environment that celebrates ingenuity, optimism, and meaningful progress — together.

Lyten offers the opportunity to do the most important work of your career — helping build the technologies that will power the next century of innovation.

Join us, and help transform industries, communities, and the planet with friends who share your drive to make a difference.