Senior Process Development Engineer (2 Positions) – Metal Powder Recycling & Additive Manufacturing
Exciting Opportunity in Advanced Manufacturing
A leading medical device company is seeking two Senior Process Development Engineers to join its dynamic Process Development Team. This role offers a unique opportunity to work on cutting-edge metal powder recycling and additive manufacturing technologies. The successful candidates will play a key role in process development, equipment qualification, material characterisation, and test method validation, ensuring seamless integration into production.
Located in Clonmel, Ireland, a thriving town known for its high quality of life, scenic landscapes, and welcoming community, this position provides an excellent environment for professional and personal growth.
Role Overview
The Senior Process Development Engineers will work cross-functionally to drive innovation, process optimisation, and technology transfer for new and existing products. This is a hands-on engineering role, collaborating with Design, Quality, and Manufacturing teams to develop robust processes that meet regulatory and operational requirements.
Key Responsibilities
Process Development & Innovation
* Lead the development of new manufacturing processes, focusing on powder blending, sampling, chemical analysis, and particle size distribution.
* Research, design, and evaluate mechanical and electro-mechanical components, assemblies, and processes.
* Conduct feasibility studies to assess the functionality and scalability of new processes.
* Develop new concepts, from initial design to commercial release, ensuring compliance with industry standards.
* Apply expertise in metal additive manufacturing and 3D printing (preferred).
Equipment Design & Validation
* Work closely with machine vendors to design, build, and test state-of-the-art manufacturing equipment.
* Ensure all equipment meets industry standards, regulatory requirements, and company specifications.
* Lead equipment validation (IQ, OQ, PQ) and process validation activities.
* Develop and execute Process Failure Mode Effects Analysis (PFMEA).
Quality & Continuous Improvement
* Drive process improvements using Lean methodologies to eliminate inefficiencies and enhance productivity.
* Collaborate with cross-functional teams to ensure all quality and regulatory documentation is accurate and complete.
* Support intellectual property (patents) submissions related to process innovations.
Technical Leadership & Collaboration
* Act as a subject matter expert in laser systems, laser materials processing (welding, marking, cutting), and CNC code/CAD/CAM (preferred).
* Lead technical reviews and mentor junior engineers.
* Coordinate validation builds, test units, and compile, analyse, and report results.
Qualifications & Experience
Level 8 engineering degree (Mechanical, Manufacturing, Materials, or related discipline).
5+ years’ experience in a regulated GMP environment (Medical Device, Pharma, or similar).
Strong knowledge of process validation (IQ, OQ, PQ), Lean methodologies, and process improvement.
Experience with metal additive manufacturing, 3D printing, and laser processing (highly desirable).
Ability to work effectively with vendors, cross-functional teams, and global stakeholders.
Why Join Us?
Be part of an innovative team shaping the future of medical device manufacturing.
Work on cutting-edge technologies in metal powder recycling and additive manufacturing.
Enjoy excellent career progression in a global company.
Live and work in Clonmel, Ireland – a town known for its fantastic community, vibrant culture, and great work-life balance.
Ready to take your engineering career to the next level? Apply now!
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