Senior Materials Development Engineer - ELYSIS

About the position

The Senior Materials Development Engineer will leverage extensive expertise in ceramic materials and processes to lead research and development efforts that advance the technical readiness level of a ceramic electrode process for the ELYSIS™ carbon‑free smelting technology. This role serves as the technical liaison, providing data‑based decisions, guidance, and support to electrode production and industrialization teams, and reports to ELYSIS R&D management.

• Creates and executes technical programs aimed at reducing scale‑up risks for critical equipment and processes.
• Leads projects, defines objectives, develops work plans, and conducts research building on prior advances and scientific understanding of breakthrough materials.
• Provides data‑based guidance for equipment and process design that reduces risk in industrialization of ELYSIS technology.
• Supports development of technical specifications for materials and commercial‑scale equipment through continuous improvement initiatives or technology development programs that close specific knowledge gaps.
• Applies fundamental engineering principles to practical solutions in laboratory, pilot, and commercial scale environments.
• Uses root‑cause analysis tools to deliver robust, sustainable solutions to new material, process, or production issues.
• Manages project objectives by developing internal or external relationships, and controlling scopes, schedules, and budgets of vendors, service providers, or institutions.
• Organizes results in traceable formats and communicates progress through written reports, presentations, patents, and publications.

ELYSIS U.S. Research & Development facility is in the Alcoa Technical Center (ATC) located in New Kensington, PA—near Pittsburgh. The role is primarily hands‑on onsite, with opportunities for remote reporting and documentation activities.

Business‑related travel and extended assignments within Canada, France, or the United States may be required.

• Graduate degree in Materials Science & Engineering, Ceramics Engineering, or Chemical Engineering.
• 5‑10 years of relevant experience in development of ceramic materials or processes.
• Demonstrated knowledge of ceramic sintering processes, processing equipment, and process scale‑up.
• Proven project execution and management skills.
• Strong aptitude in physical, chemical, and thermal material property characterization methods and analysis.
• Experience working in collaborative, results‑driven, fast‑paced team environments.
• Strong communication, organizational, and analytical skills for data management, analysis, and results presentation.

ELYSIS is committed to an inclusive environment where all voices are heard. We welcome applicants from diverse backgrounds, including women, LGBTQIA2, mature workers, people with disabilities, and persons from all cultures. ELYSIS is an equal‑opportunity workplace.

Alcoa is a proud equal‑opportunity workplace and affirmative action employer dedicated to providing equal opportunities and equal access to all individuals regardless of gender, age, race, ethnicity, sexual orientation, gender identity, religion, nationality, disability, veteran status, and other protected characteristics under applicable law.

To request an accommodation or for help with the application process, contact Alcoa Recruiting at