Process Engineer

About Phoam Labs

Phoam Labs is a pioneering materials science company on a mission to revolutionize industries by developing sustainable, next-generation replacements for petroleum-based products. Born from groundbreaking bio-based technology developed at the University of Minnesota, our first-to-market milestone began with a compostable alternative to conventional floral foam.

We are a fast-paced, high-impact startup where innovation is at the core of everything we do. As we scale our production capacity and expand our core PLA-based foam technology to tackle wider global material challenges, we are seeking a motivated, hands-on Process Engineer to help us bridge the gap between laboratory innovation and commercial-scale manufacturing.

We are seeking a Process Engineer to drive scale-up, optimization, and day-to-day excellence of our manufacturing processes. Working at our Eden Prairie location, you will play a critical role in expanding our production capacity by working closely with our in-house Operations team and contract manufacturers. The ideal candidate will possess experience in polymer extrusion or foaming, a data-driven mindset, use of AI and a passion for bringing sustainable technologies to a global market.

• Process Scale-Up & Optimization: Develop, optimize, and scale up manufacturing processes for PLA-based compostable foams from pilot scale to full commercial production.
• Equipment & Technical Expertise: Serve as the primary technical expert for extrusion systems, manufacturing hardware, equipment operation, and facility line optimization.
• Cross-Functional Collaboration: Interface directly with the Lead R&D Scientist and materials science teams to translate formulation changes into seamless, efficient production runs.
• Quality Control & Data Analysis: Oversee extensive in-house quality control testing and characterization of manufactured foams. Collect, organize, and analyze large datasets—leveraging AI-driven tools where applicable—to accelerate optimization and report findings to technical and non-technical stakeholders.
• Operations & Team Growth: Assist in hiring, training, and supervising manufacturing personnel and technical assistants as production capacity expands.
• Safety & Compliance: Develop, implement, and maintain the highest laboratory and manufacturing safety standards in compliance with federal regulations, including OSHA.
• Intellectual Property & Grants: Support the development and protection of intellectual property for new manufacturing methods. Assist with technical documentation for state and federal research grants (e.g., in collaboration with the University of Minnesota).

• Education: Bachelor’s degree in Chemical Engineering, Mechanical Engineering, Materials Science, or a closely related engineering field.
• Experience: Proven hands‑on experience in a manufacturing environment, specifically dealing with commercial-scale production, pilot lines, or scale-up operations.
• Technical Agility: Working knowledge of polymer processing, specifically extrusion, molding, or foaming technologies.
• Data & Tech Savvy: Strong organizational skills with a demonstrated ability to leverage modern software or AI applications to accelerate process data analysis and efficiency.
• Startup Mindset: Ability to work independently with minimal supervision in a fast-paced environment, with a willingness to wear multiple hats to achieve team goals.
• Cross-Functional Collaboration: Serve as a process engineering resource, effectively collaborating with manufacturing, engineering, and business development teams.
• Eligibility: Ability to work in the United States without requiring visa sponsorship.
• Travel: Ability to travel domestically and internationally (