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DuPont SpectrumPosted 3 weeks ago

Principal Process Development Engineer - Extrusion

On-siteSandy, Utah, United States

Full TimeSenior Level

Job Summary

Establish and institutionalize best-in-class process development standards, guidelines, and technical frameworks for single-lumen, multi-lumen, co-extrusion, and micro-extrusion processes across manufacturing sites. Serve as the enterprise-wide technical authority on extrusion technologies, providing expert guidance on material behavior, tooling design, and process optimization while leading root cause investigations for critical issues. Develop standardized methodologies, process characterization protocols, and design guidelines for die and downstream equipment integration, defining critical process parameters and control strategies aligned with scientific engineering principles. Partner with Product Development, Operations, Quality, and Application Development teams to ensure seamless technology transfer and standardize best practices across extrusion plants. Mentor engineers and technicians in extrusion science, deliver training programs, and drive the adoption of advanced technologies and digital monitoring solutions. Ensure all processes meet FDA and ISO 13485 regulatory requirements while supporting validation strategies for Class II and Class III medical device components.

Required Qualifications

  • Bachelor's degree in Plastics Engineering or Polymer Engineering or Mechanical Engineering
  • M.S, Ph.D.
  • 15+ years of hands-on experience in extrusion process development
  • medical device manufacturing
  • Micro-extrusion and tight-tolerance tubing
  • Multi-lumen and co-extrusion processes
  • Processing of advanced polymers (e.g., PEEK, TPU)
  • Proven track record of developing and implementing process standards and scalable solutions across multiple sites
  • Strong understanding of Polymer rheology and material science
  • Tooling/die design and flow dynamics
  • Scientific extrusion principles and DOE methodologies
  • Experience with process monitoring, automation, and data analytics tools
  • Experience in medical-grade thermoplastic materials
  • Experience integrating digital manufacturing / IIoT systems into extrusion processes
  • Experience with additional polymer processing techniques

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