R&D Associate - Advanced Manufacturing and Characterization of Polymer Composites

Requisition Id15886

We are seeking an R&D Associate who will lead and execute research focused on processing-structure-property relationships, advanced manufacturing scale-up, and experimental validation of high-performance polymer composite systems. This position resides in the Composites Innovation Group in the Manufacturing Science Division, Energy Science and Technology Directorate, at Oak Ridge National Laboratory (ORNL).

• Conduct independent and team-based research on processing-structure-property relationships to enable the integration of novel polymer composite materials into advanced manufacturing workflows
• Apply experimental expertise in composite conversion "Integrated" processes
• Develop and apply high-rate manufacturing processes for composites including injection molding (IM), compression molding (CM), thermoforming, and sheet molding compound (SMC)
• Lead and manage multifunctional materials research projects, including planning, execution, and delivery of technical milestones
• Design, develop, and execute experimental programs to support composite material processing, conversion, and performance validation
• Conduct research on high-rate manufacturing of polymer composites for industrially relevant applications
• Lead research in composite joining technologies, with emphasis on ultrasonic welding and advanced joining methods
• Support scale-up research from laboratory to pilot- and production-scale manufacturing environments
• Perform research on large-format additive manufacturing (LFAM) processes for polymer and composite systems
• Apply overmolding techniques for composite structures, including hybrid and multi-material systems
• Utilize advanced characterization methods to evaluate multifunctional materials, including mechanical, thermal, and microstructural behavior
• Perform failure analysis and process-property correlation to guide material and process improvements
• Maintain high scientific productivity through collaboration, innovation, and research excellence
• Engage with senior scientists, academic partners, and industry collaborators, and prepare technical reports, publications, and invention disclosures
• Ensure compliance with environmental, safety, health, and quality program requirements
• Deliver ORNL’s mission by aligning behaviors, priorities, and interactions with our core values of Impact, Integrity, Teamwork, Safety, and Service. Promote equal opportunity by fostering a respectful workplace - in how we treat one another, work together, and measure success.

• A PhD in materials science and engineering, mechanical engineering, polymer science, aerospace engineering, or a related discipline.
• Two years of post-PhD research or equivalent industrial R&D experience in polymer composites or advanced manufacturing
• Proven ability to lead technical tasks and contribute to multidisciplinary research programs

• Experience leading experimental development, test planning, and validation strategies for composite manufacturing processes
• Experience with high-rate composite manufacturing and scale-up research
• Expertise in composite joining technologies, including ultrasonic welding
• Experience with injection molding, compression molding, thermoforming, SMC, and overmolding processes
• Experience with large-scale additive manufacturing of polymers and composites
• Background in multifunctional materials and advanced material characterization techniques
• Experience with failure analysis and process-property correlation
• Demonstrated record of peer-reviewed publications, technical reports, or patents
• Excellent written and oral communication skills
• Motivated self-starter with the ability to work independently and to participate creatively in collaborative teams across the laboratory
• Ability to function well in a fast-paced research environment, set priorities to accomplish multiple tasks within deadlines, and adapt to ever changing needs

For employment at Oak Ridge National Laboratory (ORNL), a Real  form of identification will be required. Additionally, ORNL is subject to Department of Energy (DOE) access…