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

Requisition

Overview:

We are seeking an R&D Associate Staff - Advanced Manufacturing and Characterization of Polymer Composites who will lead and execute research focused on experimental, computational modeling, and the establishment of processing-structure-property relationships for advanced polymer composite systems. The successful candidate will support the development of predictive tools, digital manufacturing capabilities, and data-driven approaches to accelerate the design, optimization, and scale-up of high-performance composite manufacturing processes.

This position resides in the Composites Innovation Group within the Manufacturing Science Division, Energy Science and Technology Directorate, at Oak Ridge National Laboratory (ORNL).

Major Duties/Responsibilities:

* Conduct independent and team-based research on processing-structure-property relationships to enable the integration of novel polymer composite materials into advanced manufacturing workflows.

* 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.

* Conduct research on high-rate manufacturing of polymer composites for industrially relevant applications.

* Lead the development and application of computational modeling, simulation, and data-driven tools for advanced composite manufacturing processes and structures.

* Develop software, coding frameworks, and digital workflows for process modeling, material behavior prediction, design optimization, and manufacturing decision support using languages such as Python, MATLAB, C++, or similar platforms.

* Perform research on physics-based, data-driven, and hybrid modeling approaches for composite manufacturing processes, including additive manufacturing, joining, molding, and multifunctional materials.

* Support the development of digital twins, machine learning, artificial intelligence, and predictive analytics capabilities for advanced manufacturing systems and composite structures.

* Design and execute experimental validation activities to verify and improve modeling and simulation tools, including correlation of mechanical, thermal, microstructural, and manufacturing process data.

* Utilize advanced characterization and testing methods to generate validation datasets and establish processing-structure-property-performance relationships for composite materials and manufacturing processes.

* 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.

Basic Qualifications:

* A PhD in Materials Science and Engineering, Mechanical Engineering, Polymer Science, Aerospace Engineering, or a related discipline.

* 2 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.

Preferred Qualifications:

* Experience leading experimental development, test planning, and validation strategies for composite manufacturing processes.

* Experience with high-rate composite manufacturing and scale-up research.

* Experience with injection molding, compression molding, thermoforming, SMC, and overmolding processes.

* Strong programming and software development skills (e.g., Python, MATLAB, C++, Julia, or similar) for engineering analysis, process modeling, data analytics,…