Senior Materials Engineer, Thermoplastics and Compounding

Lyten, Inc.; United States; On-site; USD 117,000 - 175,000; Full time

Job summary

Lyten, Inc. is seeking an experienced materials engineer to design and develop thermoplastic formulations and drive the upstream half of product development. You will compound, test, and print with new materials, diagnosing issues and delivering a first product ready for handoff to launch.

The role requires deep polymer processing knowledge, experience with twin screw extrusion, and the ability to work across materials science, manufacturing, and customers. Travel to supplier sites is expected.

Qualifications

• BS with 5+ years of experience, MS with 3+ years, or PhD in Polymer Science, Polymer/Chemical Engineering, Materials Science or related field.
• Working knowledge of polymer structure–property relationships and polymer rheology and applying it to production and development problems.
• Hands-on experience with thermoplastic compounding and melt processing, particularly twin screw extrusion, in production or scale-up.

Responsibilities

• Design and develop thermoplastic and filament formulations to meet performance, processability and cost targets.
• Lead compounding and extrusion development from lab and pilot scale through first runs at contract manufacturers and toll processors.
• Characterize materials using rheology, thermal analysis and mechanical testing and use data to guide formulation and process decisions.
• Print with and test new materials to evaluate printability and performance and trace issues to material or 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.
• Collaborate with Product Manager on a clean handoff to launch and document learnings for knowledge sharing.

Skills

Polymer rheology

Material design

Problem solving

3D printing

Supplier communication

Education

Polymer Science

Polymer/Chemical Engineering

Materials Science

Tools

Twin screw extrusion

Melt processing

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: Pay Transparency Disclosure: 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 may deem appropriate in order to ensure compliance with applicable government access control restrictions.

Lyten is an equal opportunity employer.

Lyten is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, religion, colour, 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.

What You’ll Find at Lyten

• 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.

Company Overview

Founded in 2015 in Silicon Valley, California, Lyten is transforming the future of energy and materials innovation to build a stronger and more resilient world. Our breakthrough innovation, Lyten 3D Graphene™ is a brand‑new supermaterial that enables the creation of products that perform better and cost less. Lyten is rapidly scaling operations across the U.S. and Europe. Our lithium‑sulfur (Li‑S) batteries free from nickel manganese cobalt and graphite deliver higher energy density and lighter weight while enabling a more secure independent supply chain and a next‑generation alternative to traditional lithium‑ion chemistry. The acquisition of Northvolt’s assets in California Poland Sweden and Germany has established a strong foundation for Lyten’s global energy storage growth including Europe’s largest Battery Energy Storage System BESS manufacturing facility. Beyond battery systems Lyten’s platform technology extends to high‑performance concrete admixtures advanced composites adhesives and sensors redefining material performance across industries from automotive and aerospace to construction and defense. Lyten has raised over $625 million in equity and received support from the U.S. Export‑Import Bank to provide up to $650 million in financing for international customer energy storage projects. Recognised as one of Fast Company’s “Most Innovative Energy Companies,” one of TIME’s “Top Green Technology Companies” and a Silicon Valley Defense Group Top 100 National Security Company Lyten is leading the next wave of high‑performance materials and energy systems that enhance energy security and supply chain resilience. Our lithium‑sulfur batteries have been selected to power Chrysler’s Halcyon Concept EV. Behind every Lyten innovation is a world‑class team of scientists engineers and business leaders from some of the most respected technology energy and manufacturing companies all united by a shared mission to make a lasting global impact. We’re entering an exciting growth phase expanding production launching new products and hiring exceptional talent across engineering operations manufacturing and commercialization.