Staff Engineer Medical Devices

Staff Engineer, Additive Manufacturing

This position is hybrid based out of our Raynham, MA office location. The Staff Engineer 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 defining and creating the build files, identifying ideal print slicing specifications, some printer operation activities, 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, with the Staff Engineer collaborating closely with cross functional teams—including Manufacturing Innovation, Quality, Validation, and Maintenance. The role involves developing and supporting value stream projects, ensuring alignment, standardization, and best practice implementation across the network.

You will be responsible for:

• Leading end to end Additive Manufacturing process development and industrialization for complex processes and New Product Introductions (NPI), ensuring scalable, robust, and validated manufacturing processes.
• Creating, modifying, and optimizing LPBF build files for titanium medical implants including:
  Part orientation and nesting strategy
• Support generation and optimization to balance surface quality and removability
• Thermal management considerations for distortion-sensitive implant geometries.
• Reviewing CAD models for printability, manufacturability, and risk, providing DfAM feedback tailored to spine implants (e.g., lattice development, fixation features, anatomical surfaces).
• Maintaining build documentation consistent with R&D and design control expectations.
• Being familiar with LPBF Printer Operations including Machine setup, calibration, and pre-build checks
• Titanium powder handling, recycling, and traceability
• Build execution, monitoring, and first-level troubleshooting
• Part Removal, Post-Processing & Inspection
• Identifying print anomalies relevant to implant manufacturing (distortion, support failure, surface defects).
• Supporting continuous improvement of AM processes, SOPs, and internal best practices for medical titanium printing.
• Performing preliminary inspection and documentation:
  Visual inspection and defect classification
• Basic dimensional verification
• Identification of risks impacting downstream testing (mechanical, fatigue, coating, etc.)
• Prototype Feedback & R&D Iteration
• Providing clear, structured feedback from each build to inform:
  Design revisions
• Build orientation and support changes
• Parameter and layout refinements
• Partnering closely with Spine R&D engineers, Designers, and manufacturing teams to accelerate prototype learning cycles.
• Leading cost reduction and productivity initiatives (scrap/rework reduction, throughput improvements, consumables optimization) with measurable savings and sustainability impacts.
• Providing technical mentorship to engineers and technicians, championing continuous improvement culture, and supporting capability development across the organization.

Qualifications:

• Bachelor's degree or equivalent experience in Engineering (or equivalent).
• Demonstrated 4-6 years of experience in a relevant engineering role
• Demonstrated ability in additive manufacturing/process engineering
• 3+ years of hands-on experience with metal additive manufacturing, preferably LPBF.
• Demonstrated experience creating metal AM build files (support design, part orientation, part slicing specifications, part layout).
• Experience operating industrial LPBF printers, from build file setup to completed build.
• Strong experience in structured problem solving and root cause analysis.
• Excellent technical content skills (specifications, validation protocols, change control).
• Experience leading multi-functional teams and influencing collaborators at multiple levels.
• Proven experience supporting NPI, scale-up and transfer activities.

Preferred Qualifications & Experience (Nice to Haves)

Experience specifically with titanium spinal implants or orthopedic medical devices. Familiarity with LPBF printing platforms, experience with 3DS printing platforms preferred

Experience with build prep software such as 3

Dxpert, Materialise Magics, EOSPRINT, Netfabb, nTopology, or similar. Exposure to post-processing steps commonly used in medical devices (heat treatment, HIP, surface finishing). Familiarity with calibration, maintenance practices and working closely with in-house maintenance teams. Knowledge of regulatory requirements and submissions applicable to medical device manufacturing. Prior experience mentoring/leading emerging engineers or small technical teams.