Sr Extrusion Engineer

DSJ Global; Plymouth (MN); On-site; USD 100,000 - 140,000; Full time

Job summary

DSJ Global is seeking a Senior Extrusion Engineer to lead extrusion manufacturing for medical device components in Plymouth, Minnesota. This hands-on role focuses on troubleshooting, process development, and continuous improvement on the manufacturing floor, collaborating across manufacturing, quality, R&D, and operations teams.

The ideal candidate brings a strong extrusion background, experience with process validation, tooling development, polymer processing, and regulated environments.

Qualifications

• Experience leading extrusion processes in a regulated medical device environment.
• Knowledge of IQ/OQ/PQ validations and process development.
• Ability to design tooling/fixtures and develop capital equipment.
• Strong collaboration with manufacturing, quality, R&D, and operations.

Responsibilities

• Lead IQ/OQ/PQ validations for extrusion processes.
• Optimize extrusion processes to reduce scrap and improve yield.
• Develop custom tooling and fixturing solutions for manufacturing.
• Support new product introductions and equipment evaluations.
• Transfer products from development to full-scale production and lead floor troubleshooting.

Skills

Extrusion manufacturing

Process validation

Tooling development

Polymer processing

Regulated manufacturing

Continuous improvement

Job description

Our client is seeking a Senior Extrusion Engineer to join their medical device manufacturing operation in Plymouth, Minnesota. This individual will serve as the technical leader for extrusion manufacturing processes, supporting the production of highly engineered catheter and guidewire components used in critical medical applications. The role is focused on driving process excellence through troubleshooting, validation, process development, and continuous improvement initiatives while working closely with manufacturing, quality, R&D, and operations teams. As the site's extrusion subject matter expert, the engineer will play a key role in expanding manufacturing capabilities, improving operational performance, and ensuring products meet the highest quality and regulatory standards. This is a highly hands‑on position that requires a strong presence on the manufacturing floor, leading technical problem‑solving efforts, supporting technicians and engineers, and driving projects from concept through implementation.

The ideal candidate will bring a strong background in extrusion manufacturing, preferably within the medical device industry, along with experience in process validation, tooling development, polymer processing, and regulated manufacturing environments. Responsibilities include leading IQ/OQ/PQ validations, optimizing existing processes, supporting new product introductions, developing custom tooling and fixturing solutions, and identifying opportunities to reduce scrap and improve efficiency. The engineer will also help evaluate and implement new equipment, support capital projects, and assist with transferring products from development into full-scale production. This opportunity offers significant visibility across the organization and provides the chance to make a direct impact on innovative medical technologies that improve patient outcomes. Candidates who enjoy solving complex engineering challenges, leading continuous improvement initiatives, and working in a collaborative, fast‑paced manufacturing environment will find this to be an exciting and rewarding career opportunity.