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

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

Job summary

BD is hiring a Staff Engineer for New Product Development in Franklin Lakes, NJ. This hybrid role leads industrialization and manufacturing scale-up of TPE formulations from development to production, turning innovative materials into robust manufacturing processes.

You will drive DOE, process validation, and risk analyses, collaborate with R&D, Quality, Operations, and suppliers, and mentor engineers while delivering scalable, compliant manufacturing solutions.

Qualifications

• Bachelor's degree in materials science, polymer science, chemical engineering, mechanical engineering, plastics engineering, or a related technical field.
• Advanced technical experience in polymer or elastomer process development, manufacturing scale‑up, molding, validation, or material industrialization.
• Demonstrated experience applying DOE and engineering statistics to manufacturing or product‑development problems.
• Experience developing process windows, material specifications, validation strategies, and technically rigorous reports.
• Strong written and verbal communication skills with suppliers, manufacturing teams, technical specialists, and senior leaders.
• Proven ability to lead complex technical work across organizational and functional boundaries.

Responsibilities

• Lead industrialization of primary and backup TPE formulations from laboratory development through pilot-scale and production-scale manufacturing.
• Develop and implement scale-up strategies for compounding, pelletizing, molding, finishing, sterilization, assembly, packaging, and storage.
• Establish robust manufacturing process windows and document relationships among formulation, processing, and performance.
• Evaluate material behavior across component sizes and determine if a common formulation platform can be used.
• Lead prototype and engineering builds using representative molds, equipment, materials, and operating conditions.
• Characterize shrinkage, dimensional stability, rheology, friction, and sterilization response; perform process variation analyses.
• Translate development findings into manufacturing controls, operating ranges, setup requirements, inspection methods, and acceptance criteria.
• Support equipment qualification and validation (IQ/OQ/PQ) strategies.
• Lead root cause investigations and implement corrective actions.

Skills

DOE & statistics

Process development

Industrialization

Cross-functional leadership

Mold & manufacturing

Education

Bachelor's degree in engineering

Master's degree preferred

Tools

IQ/OQ/PQ

Statistical software

Job description

BD is hiring a Staff Engineer for New Product Development in Franklin Lakes, NJ. This hybrid role leads industrialization and manufacturing scale-up of TPE formulations from development to production, turning innovative materials into robust manufacturing processes.

You will drive DOE, process validation, and risk analyses, collaborate with R&D, Quality, Operations, and suppliers, and mentor engineers while delivering scalable, compliant manufacturing solutions.