Materials & Process Engineer

We are seeking a mid-level Materials & Process Engineer focused on manufacturing complex parts made from polymers and composites that push the boundaries of what's possible. This role centers on solving challenging part production problems by designing and building whatever equipment and process necessary to make build ultra-lightweight and load carrying structures. This role will be located in Saratoga, CA.

What you'll be doing:

• Complex Part Engineering
• Engineer solutions for producing parts with complex geometries, tight tolerances, and demanding specifications.
• Solve process design challenges for parts with undercuts, variable wall thickness, multi-material construction, and precision features.
• Develop approaches for parts that others consider unmanufacturable, with focus on volume production capability.
• Work with advanced polymer and composite materials to create high-performance components for large-scale manufacturing.
• Problem-Solving Through Equipment Development
• Build whatever equipment is needed to make complex parts work - forming presses, custom tooling, specialized fixtures, and high-throughput processing equipment
• Create SolidWorks models and detailed drawings with proper GD&T for tooling and equipment designed for high volume processes.
• Machine, weld, and assemble custom solutions when off-the-shelf equipment won't suffice for production requirements
• Prototype rapidly until parts meet specifications consistently and processes are ready for scale-up
• Part Development & Manufacturing Solutions
• Take on part challenges that require innovative manufacturing approaches capable of high-volume production
• Design and build forming processes for complex brackets, housings, structural components, and precision assemblies with polymer and composite materials
• Solve inserts, handling, and quality control challenges for difficult geometries in production environments
• Develop repeatable, high-volume processes for complex parts that can efficiently scale to large production runs
• Hands-On Implementation
• Build and test whatever tools, fixtures, and equipment are needed to make parts work at production volumes
• Troubleshoot part quality issues and implement design solutions for volume manufacturing
• Work directly with prototype parts to understand manufacturing constraints and scale-up opportunities for polymer and composite components

What you will bring to this role:

• Bachelor's degree in Mechanical Engineering, Materials Engineering, or related technical field
• 3-6 year's experience solving complex part manufacturing challenges with focus on scalable processes
• Expert-level SolidWorks skills including advanced modeling, drawings, and GD&T application
• Experience with advanced materials and high-volume forming processes such as thermosets, thermoplastics, elastomers.
• Hands-on fabrication skills: machining, welding, assembly, and creative problem-solving
• Track record of solving challenging manufacturing problems while maintaining production viability

Essential Skills:

• Part-focused thinking: ability to reverse-engineer manufacturing solutions from part requirements with volume production in mind
• SolidWorks: advanced modeling for complex parts and custom tooling solutions designed for production scale
• GD&T: proper application for complex parts with challenging tolerance requirements in volume manufacturing
• Creative problem-solving: building non-standard solutions for unique part challenges that work at scale
• Hands-on fabrication: whatever skills are needed to make the solution work in production
• Materials expertise: understanding polymer and composite material behavior in complex, high-volume forming applications
• Production scaling: experience transitioning prototype processes to efficient, large-volume manufacturing

What Sets You Apart:

• You see a complex part and immediately start thinking about how to make it efficiently at volume
• You're not limited by existing equipment - you build what's needed to solve the problem for production scale
• You thrive on part challenges that others walk away from, especially when volume production is required
• You understand that the equipment is just a tool to achieve the real goal: perfect parts at production quantities
• You can take a challenging part specification and deliver a working manufacturing solution ready for large-scale production
• You think about scalability, cycle times, and production economics from day one
• Collaborative environment with part designers, manufacturing teams, and production engineers

Additional Requirements

This is a fast-paced, high-impact environment - flexibility to occasionally work extended hours or weekends during critical periods is expected.