Staff Engineer, TPE Industrialization & Scale-Up (Hybrid)

BD; Branchburg Township (NJ); Hybrid; USD 136,000 - 217,000; Full time

Benefits offered by this job

Medical coverage

Dental coverage

Vision coverage

Paid time off

Job summary

BD is seeking a Staff Engineer/New Product Development to drive TPE material industrialization and manufacturing scale‑up in Franklin Lakes, NJ. This hybrid role focuses on turning innovative formulations into robust, validated manufacturing processes and leading cross‑functional teams.

The position requires advanced experience in polymer/elastomer development, DOE, and process validation, with strong communication skills for liaising with suppliers, R&D, quality, and operations.

Qualifications

• Bachelor’s degree or equivalent in materials science, polymer science, chemical engineering, mechanical engineering, plastics engineering, or related field.
• Experience in polymer/elastomer process development, manufacturing scale‑up, molding, validation, or material industrialization.
• Experience applying DOE and engineering statistics to manufacturing or product‑development problems.
• Ability to develop process windows and material specifications; lead rigorous reports.
• Strong communication with suppliers and cross‑functional teams; lead complex technical work.

Responsibilities

• Lead industrialization of primary and backup TPE formulations from laboratory to pilot and production scale.
• Develop scale‑up strategies for compounding, pelletizing, molding, finishing, sterilization, assembly and packaging.
• Establish process windows; relate formulation to processing, geometry and performance.
• Lead prototype builds; assess shrinkage, rheology, and variability across sizes.
• Apply DOE, Gage R&R, regression, and process‑capability analyses; support validation.
• Translate findings into production controls and acceptance criteria.
• Lead root cause investigations and implement corrective actions.
• Provide technical leadership and documentation across functions.

Skills

Process development

Scale-up manufacturing

DOE

Statistical engineering

Cross-functional collaboration

Education

Bachelor’s degree in materials science or related field

Tools

IQ/OQ/PQ

Statistical analysis

Job description

BD is seeking a Staff Engineer/New Product Development to drive TPE material industrialization and manufacturing scale‑up in Franklin Lakes, NJ. This hybrid role focuses on turning innovative formulations into robust, validated manufacturing processes and leading cross‑functional teams.

The position requires advanced experience in polymer/elastomer development, DOE, and process validation, with strong communication skills for liaising with suppliers, R&D, quality, and operations.