Sr. Materials Engineer, R&D Core Materials

Sr. Materials Engineer, R&D Core Materials

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Department: Research & Development

Location: US-California-San Jose

Compensation: $149,800 - $206,000 / year

Align Technology, Inc. is seeking a Senior Materials Engineer with deep expertise in polymer science, sustainability, material compatibility, and medical device packaging to lead complex, cross‑functional projects spanning orthodontic accessory and ancillary product compatibility, recycled materials innovation, and advanced packaging development.

This role serves as a technical leader and subject‑matter expert (SME) who defines testing strategy, establishes technical direction, and partners across the organization to translate material innovations into scalable, compliant, and sustainable product solutions.

You will collaborate across R&D, eCommerce, Manufacturing, Regulatory, Quality, Legal, and Supply Chain to deliver robust material solutions that enable Align’s growth and sustainability goals.

• Lead and own material selections and studies for orthodontic accessory and ancillary products to ensure safety, functionality with Invisalign orthodontic appliances, and packaging.
• Drive the development of circular‑material technologies by transforming recycled polymers into high‑performance, qualified applications.
• Design, evaluate, and optimize medical and consumer packaging for performance, manufacturability, and sustainability in accordance with ISO 11607 and ASTM/ISTA standards.
• Design and perform standard and customized polymer characterization (thermal, mechanical, rheological, spectroscopic) and long‑term reliability evaluations.
• Define and approve material specifications; author validation protocols and reports documentation per Design Control and QMS requirements.
• Lead collaboration with internal teams and external partners to evaluate, qualify, and scale sustainable materials and packaging solutions globally.
• Support chemical‑compliance and biocompatibility evaluations to ensure regulatory readiness and provide data for product filings.
• Translate complex test results into clear technical reports, risk assessments, and strategic recommendations that guide product and business decisions.
• Mentor and coach engineers and technicians to strengthen experimental design, data integrity, and sustainability best practices across the materials function.

• M.S., or Ph.D. degree in Polymer Science, Materials Science, Chemistry, Chemical Engineering, or related discipline.
• 8+ years of R&D experience involving polymers, packaging, or medical devices.
• Proven expertise in polymer characterization, structure–property analysis, and material compatibility evaluation.
• Must have the technical abilities to apply results to product performance metrics.
• Strong background in sustainability and recycled materials development, including processing, evaluation, and qualification for value‑added applications.
• Hands‑on experience in packaging materials design, development, and validation for medical or consumer products.
• Excellent technical communication and cross‑functional collaboration skills.
• Strong analytical thinking and ability to translate data into practical engineering recommendations.
• Demonstrated ability to manage multiple projects and influence cross‑functional stakeholders.
• Demonstrated learning agility, ownership, and a proactive, results‑driven mindset.
• Ability to take initiative, follow through, and approach challenges with curiosity and persistence in a fast‑paced environment.
• High standards of execution, integrity, and accountability, with a strong commitment to achieving results and goals.

• Experience evaluating material interactions for chemical and functional compatibility with medical devices and packaging systems.
• Knowledge of environmental, chemical, and packaging compliance standards, including REACH, RoHS, Prop 65, TSCA, ISO 10993, and ISO 11607.
• Familiarity with sustainable packaging materials, validation methods, and relevant ASTM and ISTA test standards (e.g., ASTM F88, F1980; ISTA 3A).
• Working knowledge of design control,…