Senior Staff Consultant (Metallurgy)

Engineering Systems Inc.; Kansas City (MO); Hybrid; USD 110,000 - 170,000; Full time

Benefits offered by this job

Life Insurance/Voluntary Life/ULI

401k with employer match

Flexible Time Off

10 paid holidays

Work/Life Balance

Wellness Reimbursement

Career growth & continuing education

Pet Insurance

Job summary

Engineering Systems Inc. in Kansas City, MO, seeks a seasoned Materials/Metallurgical Engineer to lead forensic failure analysis and support complex investigations for clients across industries.

You will perform metallurgical testing, review literature, write technical reports, and present findings to clients and internal teams. The role requires 5–10 years in materials research or forensic consulting and strong communication skills. Travel and mentoring responsibilities are included.

Qualifications

• Bachelor's in Metallurgical Engineering, Materials Engineering, and/or Materials Science or related field is required.
• Master’s or Ph.D. in Metallurgical Engineering, Materials Engineering, and/or Materials Science or related field is preferred.
• Professional Engineer (P.E.) license preferred, or willingness to obtain
• CWI, CQE, API certifications are a plus
• Experience and familiarity with metallurgical/materials laboratory procedures and testing; capable of directing staff in performing high‑quality lab work
• Knowledge of fractography and metallography techniques
• Experience with SEM/EDS analysis and related laboratory equipment

Responsibilities

• Perform forensic, root-cause failure analysis in industrial, insurance, and/or litigation projects as part of a team environment
• Write technical reports, communicate effectively with clients, perform research and present technical material clearly and concisely to clients and internal colleagues
• Ability to review and understand technical literature and reports
• Perform both traditional and case-specific testing and/or analysis
• Confer with project staff to outline work plan and to assign duties, responsibilities, and scope of work
• Coordinate activities of project personnel to ensure project progresses on schedule and within prescribed budget
• Potential to testify in deposition or trial in litigation matters as an expert witness
• Confer with project personnel to provide technical advice and to resolve problems
• Travel as required for project work and business and professional development events

Skills

Technical writing

Client communication

Team leadership

Multidisciplinary collaboration

Problem solving

Education

Bachelor in Metallurgical Engineering / Materials Engineering / Materials Science

Master's or PhD in Metallurgical Engineering / Materials Science

Tools

SEM with EDS analysis

Job description

If you are unable to complete this application due to a disability, contact this employer to ask for an accommodation or an alternative application process.

Full Time Kansas City, Kansas City, MO, US

About ESi

Engineering Systems Inc. (ESi) is an engineering and scientific investigation and failure analysis firm. We are frequently retained by law firms, insurance companies, and manufacturers to answer complex technical questions on projects ranging from small, focused investigations to large-scale, high-profile losses.

Our work spans a wide range of challenges, including major transportation accidents, equipment and product failures, personal injury claims, and damage to residential, commercial, and industrial structures. The variety, complexity, and real-world impact of our projects create deeply fulfilling and intellectually engaging careers for our consultants.

At ESi, you’ll have the opportunity to shape your own path while being supported by a collaborative culture, national expertise, and industry-leading resources.

Why ESi

ESi’s Materials Practice focuses on hands-on failure analysis and advanced materials characterization across industries. With access to a network of in‑house laboratories, engineers evaluate material behavior and performance in a collaborative environment that emphasizes technical rigor and continuous development.

Key Responsibilities

• Perform forensic, root cause failure analysis in industrial, insurance, and/or litigation projects as part of a team environment
• Write technical reports, communicate effectively with clients, perform research and present technical material clearly and concisely to clients and internal colleagues
• Ability to review and understand technical literature and reports
• Perform both traditional and case‑specific testing and/or analysis
• Confer with project staff to outline work plan and to assign duties, responsibilities, and scope of work
• Coordinate activities of project personnel to ensure project progresses on schedule and within prescribed budget
• Potential to testify in deposition or trial in litigation matters as an expert witness
• Confer with project personnel to provide technical advice and to resolve problems
• Travel as required for project work and business and professional development events

Qualifications

Education / Certifications / Licenses Required

• Bachelors in Metallurgical Engineering, Materials Engineering, and/or Materials Science or related field is required
• Master’s or Ph.D. in Metallurgical Engineering, Materials Engineering, and/or Materials Science or related field is preferred
• Professional Engineer (P.E.) license preferred, or willingness to obtain
• CWI, CQE, API certifications are a plus

Experience Required

• 5-10 years of experience in materials/metallurgical research, forensic consulting, materials/metallurgical engineering, or a related field
• Experience and familiarity with metallurgical/materials laboratory procedures and testing and capable of directing staff in performing high-quality lab work
• Experience in materials failure analysis with a focus on metallurgy, materials science, and mechanics of materials
• Knowledge of fractography and metallography techniques
• Experience in utilizing a scanning electron microscopy (SEM) with X‑ray energy dispersive spectroscopic (EDS) analysis capability in addition to the ability to direct staff in performing
• Experience and/or knowledge of analytical techniques and laboratory equipment related to failure of metals and alloys, including optical microscopy, metallography, and sample preparation
• Experience or exposure to insurance claims and/or product liability matters preferred
• Ability to conduct litigation consultation and interact with attorneys, adjusters, and paralegals
• Deposition and trial experience as an expert witness, or a willingness to become a testifying subject matter expert
• Excellent technical and critical thinking skills

Other Technical & Non-Technical Skills

• Excellent written and oral communication skills and ability to effectively communicate complex technical topics and findings to a wide variety of audiences
• A team player actively engaging others in accomplishing project work and office goals both within their home office as well as across offices and other technical disciplines throughout ESi
• Basic understanding of other technical and engineering disciplines for effective collaboration and partnership on multidisciplinary teams
• Ability and desire to market ESi and grow the materials failure analysis specialty
• Ability and desire for career advancement

What We Can Offer You

We believe great work happens when people feel supported, challenged, and trusted. Some of the benefits we offer include:

• Life Insurance/Voluntary Life Insurance/Universal Life Insurance
• 401k with employer match
• Flexible Time Off (FTO) – encouraged to take 20 days of paid time off/year
• 10 paid holidays (9 standard holidays and 1 floating holiday)
• Work/Life Balance in a collaborative working environment
• Wellness Reimbursement
• Career growth & continuing education opportunities
• Pet Insurance

Compensation will be made up of a competitive base salary as well as bonus potential determined by your own individual performance and the performance of the organization overall.

Physical Demands:

This role requires frequently sitting or standing for extended periods of time and occasionally lifting and/or moving items weighing up to 50 pounds, with infrequent lifting up to 75 pounds. The work regularly requires bending, twisting, kneeling, crouching, and maintaining balance. This position frequently requires handling and operating specialized tools and equipment and working in a variety of physical positions, including occasionally accessing tight or confined spaces.

The physical demands described here are representative of those that must be met to successfully perform the essential functions of this position. Reasonable accommodations may be made to enable individuals with disabilities to perform these essential functions.

Work is performed in both office and field environments, including active construction sites, industrial settings, and damaged or compromised structures. The work environment may include exposure to varying noise levels, weather conditions, uneven terrain, and site‑specific hazards. Use of personal protective equipment (PPE) may be required depending on site conditions.

The work environment characteristics described here are representative of those an employee may encounter while performing the essential functions of this position. Reasonable accommodations may be made to enable individuals with disabilities to perform these essential functions.

ESi is an equal opportunity employer committed to attracting and retaining the most qualified individuals based on merit, experience, and skills. Employment decisions are made without regard to race, ethnicity, color, religion, national origin, sex, sexual orientation, age, disability, or veteran status. In accordance with applicable laws, ESi actively supports the employment of veterans and individuals with disabilities.