Senior R&D Thermoplastic Manufacturing Engineer (Startup)
Job Title: Senior R&D Thermoplastic
Manufacturing Engineer (Startup)
Experience: 2–5 years industry experience (or PhD + relevant research)
Education: Minimum M.S.(PhD strongly preferred)
Department: Advanced Manufacturing / R&D
Reporting To: CTO / VP Engineering / Founder
Position Summary
We are an early-stage aerospace composites
startup developing next-generation thermoplastic composite structures for civil
and defence applications. We seek a highly capable R&D engineer who can
convert cutting-edge materials and manufacturing concepts into scalable
production-ready processes.
This role requires both deep technical
knowledge and strong hands-on execution. The candidate must be comfortable
working in an unstructured startup environment, moving between laboratory
experimentation, process development, tooling design, factory setup, and
customer demonstrations.
Key Responsibilities
- Lead development of novel thermoplastic composite manufacturing
processes from concept to pilot production.
- Build and optimize manufacturing methods including:
- Thermoforming
- Compression molding
- Stamp forming
- Automated layup
- Induction / resistance welding
- Over-molding and hybrid molding
- Design and execute R&D experiments using DOE and
statistical methods.
- Establish process windows for temperature, pressure, dwell, and
cooling cycles.
- Develop methods to reduce defects such as porosity, wrinkles,
incomplete consolidation, and weld failures.
- Work directly with founders to define technology roadmap and IP
strategy.
- Evaluate new materials, suppliers, and equipment.
- Support prototype builds and customer demonstrations.
- Help build internal manufacturing labs, process documentation,
and SOPs.
- Contribute to patent disclosures, technical publications, and
proposal writing.
Requirements
Required Qualifications
- M.S. minimum; PhD preferred in engineering or materials
science.
- 2–5 years of relevant industrial experience, OR PhD with strong
applied research.
- Strong knowledge of thermoplastic composites and polymer
processing.
- Hands-on experience with high-performance polymers such as
PEEK, PEKK, PPS, and PEI.
- Familiarity with composite testing, microscopy, and failure
analysis.
- Strong analytical and experimental mindset.
Ideal Startup Candidate Traits
- Builder mentality; comfortable creating systems from scratch
- Highly hands-on in lab/shop environments
- Comfortable with ambiguity and rapid iteration
- Strong ownership mindset
- Can operate independently with minimal supervision
- Strong communication with customers, investors, and technical
partners
- Demonstrated ability to build something from zero (lab,
process, prototype, tooling, or pilot line)