Senior Manufacturing Engineer I, New Process Introduction (NPI)

Exton, PA

The Senior Manufacturing Engineer I, NPI will provide technical leadership in machine design, process development, and polymer processing to support the scale-up and commercialization of new and existing injection molding processes. The ideal candidate will bring deep technical expertise in polymer processing, with hands-on experience in injection molding of high-performance thermoplastics. This role will direct or participate in project teams within the PMP/project management process.

Key Responsibilities:

Lead the design, development, and optimization of injection molded products, with a focus on thermoplastic polyurethane and polyesters Collaborate cross-functionally with R&D, Quality and Manufacturing teams to scale up new molding processes from lab/pilot scale to commercial production Evaluate polymer material properties and performance under various processing conditions to ensure consistent, high-quality product output Identify and implement process improvements, cost-saving initiatives, and strategies to enhance production efficiency and throughput Develop and manage project plans for process development activities to generate process design information for scale-up and evaluate process technical risks Support installation, commissioning, validation (IQ/OQ/PQ), and troubleshooting of new injection molding equipment and tooling Familiarity with analytical methods (DSC, TGA, rheometry) and mechanical testing to support process understanding and material selection Provide technical expertise and support for both new process introductions and current molding processes to ensure operational excellence Update process documentation within the Engineering Change Notice process Support Manufacturing Excellence (MSA, OEE, IP, IER, and DICI) Review & approve MOCs & ECNs Review, disposition, & approve non-conformance reports, deviations, rework orders, engineering test files (ETF), design control & risk management reports We Bring: A competitive compensation package, with comprehensive health and welfare benefits A place to grow and develop A company that is purpose-led and performance-driven in a corporate culture that values people and planet The opportunity to work on growing brands and build on a strong foundation The chance to make improvements and make an impact on the business You Bring: Bachelor's or Master's degree in Engineering (Biomedical, Mechanical, Chemical, Polymer, Materials Science, or related discipline) Minimum of 7 years of experience in the medical device or related industry, with a strong focus on industrial manufacturing Demonstrated expertise in supporting application and process development as a specialist in thermoplastic injection molding Strong understanding of injection molding (including the ability to provide mold development and design review input), tooling design, and downstream processing Hands-on experience with high-temperature polymer processing and working in a cleanroom or controlled environment is highly preferred Demonstrated experience in scientific injection molding techniques and in-depth knowledge of mold flow analysis are highly desirable Proficient in the use of MS Office, Word, Excel, PowerPoint, MS Project, Minitab, CAD Software, and SharePoint Demonstrated project management experience. Ability to apply Project Management techniques according to PMP Extensive knowledge and expertise working with Engineering & Quality tools (Statistics, Lean Six Sigma, DFM, DOE) Working knowledge and experience working with the Regulatory pathways associated with IDE, 510k, PMA, & CE including the associated ISO & ASTM standards. Lean Six Sigma Green Belt certification preferred.

The salary or hourly wage scale provided reflects the pay range dsm-firmenich expects to pay the successful candidate for the position. Individual pay offered will be based on the applicant's job-related skills, experience, relevant education, or training, and primary work location.

In addition to base salary, we also offer a comprehensive total rewards package, inclusive of annual incentive pay, a retirement savings plan, health care coverage, paid time off, recognition programs and a broad range of other benefits. All benefits and incentives are subject to eligibility requirements.

About dsm-firmenich

At dsm-firmenich, we don't just meet expectations - we go beyond them. Join our global team powered by science, creativity, and a shared purpose: to bring progress to life. From elevating health to making fortified food and sustainable skincare, the impact of your work here will be felt by millions - every single day. Whether it's fragrance that helps you focus, alternative meat that's better for the planet, or reducing sugar without losing flavor, this is where you help shape the future of nutrition, health, and beauty for everyone, everywhere. And while you're making a difference, we'll make sure you're growing too. With learning that never stops, a culture that lifts you up and the freedom to move across businesses, teams, and borders. Your voice matters here. And your ideas? They're essential to our future. Because real progress only happens when we go beyond, together .

At dsm-firmenich, we believe being a force for good starts with the way we treat each other. When people feel supported, included, and free to be themselves, they do their best work - and that's exactly the kind of culture we're building. A place where opportunity is truly equal, authenticity is celebrated, and everyone has the chance to grow, contribute, and feel they belong. We're proud to be an equal opportunity employer, and we're serious about making our hiring process as fair and inclusive as possible. From inclusive language and diverse interview panels to thoughtful sourcing, we're committed to reflecting the world we serve. We welcome candidates from all backgrounds - no matter your gender, ethnicity, sexual orientation, or anything else that makes you, you. And if you have a disability or need any support through the application process, we're here to help - just let us know what you need, and we'll do everything we can to make it work.

We're managing this search directly at dsm-firmenich. If you're applying as an individual, we'd love to hear from you. We're not accepting agency submissions or proposals involving fees or commissions for this role.