Design & Additive Manufacturing Engineer, Spine R&D – DePuy Synthes

Job Function

R&D Product Development

Biomedical Engineering

Scientific/Technology

Raynham, Massachusetts, United States of America

We are searching for the best talent for a Staff Design & Additive Manufacturing Engineer, Spine R&D to join our J&J Orthopaedics team. This position is hybrid based out of our Raynham, MA office location.

Johnson & Johnson announced plans to separate our Orthopaedics business to establish a standalone orthopaedics company, operating as DePuy Synthes. The process of the planned separation is anticipated to be completed within 18 to 24 months, subject to legal requirements, including consultation with works councils and other employee representative bodies, as may be required, regulatory approvals and other customary conditions and approvals.

Should you accept this position, it is anticipated that, following conclusion of the transaction, you would be an employee of DePuy Synthes and your employment would be governed by DePuy Synthes employment processes, programs, policies, and benefit plans. In that case, details of any planned changes would be provided to you by DePuy Synthes at an appropriate time and subject to any necessary consultation processes.

The Staff Engineer position will be a dual role, with half of the time spent on Product Design within the Spine Surgeon Request Team. The other half of this role will support the development and optimization of Additive Manufacturing processes and products for R&D. Specifically, this role will own the additive manufacturing loop—from build file creation and printer operation through part removal, inspection, and structured feedback into subsequent design iterations.

This position is best suited for an engineer who is comfortable operating metal AM equipment, applying DfAM principles, and working within a regulated medical device development environment.

A key focus of the position is expanding the team’s AM capabilities, and the Staff Engineer will collaborate closely with cross‑functional teams—including Manufacturing Innovation, Quality, Validation, Maintenance, and Calibration. The role involves developing and supporting value‑stream projects, ensuring alignment, standardization, and best‑practice implementation across the network.

• Lead and contribute to the design and development of innovative medical devices and technologies supporting new custom product development and specialty product lifecycle management.
• Develop CAD models and detailed engineering drawings in accordance with company standards, including GD&T and tolerance analysis.
• Perform engineering analyses and simulations to validate design concepts and optimize performance.
• Lead or participate in cross-functional project teams as needed, and deliver technical solutions aligned with clinical (direct surgeon requests), regulatory, quality, and business objectives.
• Support design control activities and the transfer of designs from concept through prototype to production.

• Lead end‑to‑end process development and industrialization for complex processes and New Product Introductions (NPI), ensuring scalable, robust, and validated manufacturing processes.
• Build Preparation & Design-for-Additive (DfAM)
  • Create, modify, and optimize LPBF build files for titanium medical implants (e.g., Ti 6
    
    Al 4V), including:
    • Part orientation and nesting strategy
    • Support generation and optimization to balance surface quality and removability
    • Thermal management considerations for distortion‑sensitive implant geometries.
• Review CAD models for printability, manufacturability, and risk, providing DfAM feedback tailored to spine implants (e.g., lattice regions, fixation features, anatomical surfaces).
• Maintain build documentation consistent with R&D and design control expectations.
• LPBF Printer Operation
  • Will eventually own the end-to-end operation of industrial LPBF metal printers, including:
  • Machine setup, calibration, and pre-build checks
  • Titanium powder handling, recycling, and traceability
  • Build execution, monitoring, and first-level…