Transforming smiles,
changing lives.
DFM Sr Materials Engineer
The DFM Sr. Materials Engineer, Polymers is responsible for leading the evaluation, introduction, and optimization of polymer materials within manufacturing processes. This includes both the implementation of new materials and the modification of existing ones to support product and process innovation.
This role plays a critical part in ensuring material performance, process stability, and regulatory compliance by driving material characterization, test method development, and data-driven decision-making. The engineer will focus on polymers used in 3D printing and thermoforming applications—such as thermoplastics, elastomers, and thermosets—ensuring their reliability, consistency, and suitability for high-quality medical device manufacturing
Key Responsibilities
- Material Characterization:
o Perform physical, chemical, and mechanical analysis of polymer materials using techniques such as FTIR, DSC, TGA, rheometry, and stress-strain testing.
o Determine critical material properties (e.g., viscosity, curing, thermal stability) to ensure compliance with process and product requirements.
- Material Testing:
o Design and execute testing protocols to evaluate resins performance under various printing and post-processing conditions.
o Validate materials interactions with different equipment configurations and parameters.
- Material and Process Optimization:
o Collaborate with design and process engineering teams to identify areas for improvement in material performance.
o Define and propose process adjustments and material property ranges to optimize mechanical performance and functional characteristics.
- Regulatory Compliance:
o Document and analyze test results to ensure compliance with applicable regulations in the medical industry.
o Contribute to technical report writing and support process audits related to manufacturing materials.
- Innovation and Development:
o Collaborate with suppliers to test and validate new materials, ensuring their suitability for internal processes.
o Develop comprehensive Certificates of Analysis (COAs) to ensure material compliance and optimal performance in the manufacturing environment.
- Project Coordination: Leads cross-functional projects using project management methodologies (preferably AGILE/SCRUM) to:
o Define project scope and objectives
o Develop financial impact models to support business decisions
o Break down project timelines and deliverables into actionable plans
o Secure and coordinate necessary resources (human, material, and technical)
o Ensure timely execution and completion of project activities
o Actively engage with local manufacturing teams to align execution and drive implementation on the production floor.
- Process Validation:
o Defines operational ranges and process limits through the application of statistical control methodologies to ensure process robustness, scalability, and product conformity.
o Drives validation activities in compliance with ISO 13485 and internal quality systems, submitting and documenting all changes impacting material or process performance prior to their deployment in the manufacturing environment.
Skills, Knowledge & Expertise
Education:
- Bachelor's or Master's degree in Materials Engineering, Chemistry, Polymer Science, or a related field.
Technical skills
- Experience with material characterization techniques (FTIR, DSC, TGA, etc.).
- Knowledge of 3D printing technologies (SLA, DLP, or SLS preferred).
- Familiarity with regulatory standards in the medical industry (ISO 10993, FDA, etc.).
Soft Skills:
- Strong problem-solving abilities.
- Effective communication skills to present technical results.
- Critical thinking and an innovation-driven mindset.
Experience
- 3+ years in polymers material characterization, preferably with thermoplastics and resins used in 3D printing or similar applications.
- Preferable additional experience on:
- Developing and validating manufacturing processes or applications.
- Industrial-grade 3D printing systems and materials.
- Background in regulated industries such as medical devices, aerospace or automotive.
Language:
English Upper intermediate to Advance
Informazioni su Align Technology
Your growth and well-being:
At Align, every smile matters. We’re committed to helping you thrive by supporting the health, growth, and well-being of our team members through a variety of tools and programs. While specific offerings may vary by location and role, Align employees can typically expect:
At Align, every smile matters. We’re committed to helping you thrive by supporting the health, growth, and well-being of our team members through a variety of tools and programs. While specific offerings may vary by location and role, Align employees can typically expect:
- Health and well-being programs to keep you thriving in both body and mind.
- Employee-exclusive discounts on Invisalign products.
- Learning opportunities through online learning resources and support for your individual development plans.
- Inclusive, global workplace that fosters collaboration, recognition and belonging.
Country and/or role specific details will be shared with you by your recruiter during the interview process.
Discover Align:
We are a global community of game-changers and smart team players, united by our belief in the power of a smile. Our dynamic team of exceptional employees is dedicated to transforming the industry and creating extraordinary outcomes every day.
Align’s core values of agility, customer, and accountability are more than words to work by, they are words we live by. The actions we take every day speak to who we are as a company and our focus on being truly impactful. We celebrate our differences, and the many ways we support one another— ultimately creating a more inclusive organization and world as we continue transforming smiles and changing lives.
We foster a culture where thinking differently and seeking new experiences are not just encouraged but celebrated. With the Align Mindset, we empower each other, ensuring every voice is heard and valued in an inclusive environment that inspires creativity and collaboration.
At Align, we believe in the power of a smile, and we know that every smile is as unique as our employees. As we grow, we are committed to building a workforce rich in diverse cultural backgrounds and life experiences, fostering a culture of open-mindedness and compassion. We live our company values by promoting healthy people and healthy communities, all with the intent of changing millions of lives, one unique smile at a time.
As part of our commitment to innovation, Align Technology includes exocad and Cubicure, companies that enhance our offerings and extend our impact to industry transformation.
Eager to learn how we embrace our global differences and nurture employee well-being?
Explore Align's culture here!
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Equal Opportunity Statement:
Align Technology is an equal opportunity employer. We are committed to providing equal employment opportunities in all our practices, without regard to race, color, religion, sex, national origin, ancestry, marital status, protected veteran status, age, disability, sexual orientation, gender identity or expression, or any other legally protected category. Applicants must be legally authorized to work in the country for which they are applying, and employment eligibility will be verified as a condition of hire.
Review our Applicant Privacy Policy for additional information.
Equal Opportunity Statement:
Align Technology is an equal opportunity employer. We are committed to providing equal employment opportunities in all our practices, without regard to race, color, religion, sex, national origin, ancestry, marital status, protected veteran status, age, disability, sexual orientation, gender identity or expression, or any other legally protected category. Applicants must be legally authorized to work in the country for which they are applying, and employment eligibility will be verified as a condition of hire.
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