Process Engineer – New Product Introduction (NPI)

Location: San Carlos, CA

Employment Type: Full-Time, Direct Hire

Work Arrangement: 100% Onsite

About the Role

We are seeking an experienced Process Engineer – NPI to join a fast-growing advanced manufacturing organization. This role is critical in scaling innovative processes from prototype to high-volume production, enabling successful product launches in industries such as EV, energy storage, and aerospace.

You will work hands-on with cutting-edge technologies and collaborate across engineering and customer-facing teams to bridge the gap between concept and manufacturability.

Key Responsibilities

• Scale processes from prototype to high-volume manufacturing, driving yield, throughput, and cost efficiency.
• Design, implement, and validate manufacturing processes for scalability and reliability.
• Build and qualify first articles; ensure readiness for customer and internal validation.
• Conduct structured experiments and root cause analysis to de-risk scale-up.
• Develop process documentation and train staff for smooth transition to production.
• Work directly with advanced materials and high-volume manufacturing methods.

Qualifications

• Bachelor’s degree or higher in Materials Science, Physics, Chemical Engineering, Chemistry, or related field.
• 7+ years of hands-on experience in process engineering.
• Proven track record of scaling processes from prototype to production.
• Strong background in manufacturability, yield improvement, and cost reduction.
• Familiarity with advanced manufacturing methods (vacuum lamination, thermally-activated adhesives, roll-to-roll processing, material patterning, laser welding).
• Proficiency in statistical analysis and tools (JMP, Minitab).
• Ability to troubleshoot custom manufacturing and metrology equipment.
• Adaptability to fast-paced start-up environments.

Work Environment

• Onsite role in a dynamic start-up setting.
• Physical ability to lift up to 50 lbs.
• Exposure to manufacturing environments; PPE required.