Senior Process Engineer - Aerogel Manufacturing & Scale-Up

Aspen Aerogels; East Providence (RI); On-site; USD 130,000 - 150,000; Full time

Benefits offered by this job

Medical

Dental

Vision

Tuition Reimbursement

Paid Holidays

Sick Time

PTO

401k Employer Match

Life Insurance

Disability Insurance

Job summary

Aspen Aerogels, Inc. in Rhode Island seeks a Senior Process Engineer to drive manufacturing excellence in aerogel production.

You will lead the design of next-generation processes, partner with R&D and Plant Engineering, and scale new products from lab to full-scale production. The role focuses on safety, yield, cost reduction, and process reliability, with hands-on development, data analysis, and mentoring of engineering teams.

Qualifications

• BSME or BSChE degree required with manufacturing experience.
• Experience in chemical process development and silica-related operations is advantageous.
• Hands-on lab, pilot, and scale-up experience with process equipment.

Responsibilities

• Lead design of future aerogel manufacturing methods and process technologies.
• Drive transformational process changes in manufacturing with R&D for next-gen aerogel composites.
• Collaborate with R&D and Plant Engineering on product/process improvements for safety, capacity, yield, and cost.
• Transfer new technologies, products, and processes into Aspen.
• Establish project goals with Marketing and Operations.
• Lead experimental work to support scale-up and robust commercial processes.
• Analyze process and quality data to improve the manufacturing process.
• Coordinate trial manufacturing runs and troubleshoot failures.
• Provide technical guidance and training to Engineering and Manufacturing teams.
• Develop full-scale standards, procedures, and documentation for products.

Skills

Process design

Process engineering

Technology evaluation

Unit operation

Analytical methods

Chemical process development

Coating

Casting

Web handling

Oven drying

Pilot production

High-volume manufacturing

Statistics / data analysis

Education

BSME / BSChE

Job description

Aspen Aerogels, Inc. in Rhode Island seeks a Senior Process Engineer to drive manufacturing excellence in aerogel production.

You will lead the design of next-generation processes, partner with R&D and Plant Engineering, and scale new products from lab to full-scale production. The role focuses on safety, yield, cost reduction, and process reliability, with hands-on development, data analysis, and mentoring of engineering teams.