Senior Extrusion Engineer

Kforce's client, a rapidly growing medical device technology company in the Carlsbad, CA area, is seeking a Senior Extrusion Engineer to support the design, development, and manufacturing of advanced extruded components. We are partnering directly with the hiring manager on this search. The company offers a competitive total compensation package, including base salary, annual bonus, and equity (stock/RSUs). This role is onsite - 5 days/week.

Overview:
The Extrusion Engineer will play a key role across R&D, process development, and manufacturing, supporting a new production extrusion line. This role focuses on the design, development, validation, and sustainment of complex extruded tubing and components for medical device applications. You will collaborate cross functionally with R&D, Operations, Quality Engineering, and Supply Chain, while also mentoring operators and technical staff.

Key Responsibilities:

* Lead design, development, and sustainment of extruded tubing and components for medical device applications

* Evaluate performance, user, and clinical requirements and translate them into robust extrusion solutions

* Develop and optimize processes for:
Single- and multi lumen tubing;
Multi-layer tubing with wire substrate coating;
Coil- and braided reinforced tubing; PTFE lined and multi durometer sectioned tubing

* Work hands on with extrusion equipment, tooling, and systems, including:
Extruders, pump systems, dryers, ovens;
Unwind/rewind loaders, vacuum tanks, pullers/cutters;
System controls and fixtures

* Lead installation, qualification, and validation of manufacturing equipment, including documentation (IQ/OQ/PQ, specifications, procedures)

* Drive improvements in yield, efficiency, and process capability

* Partner with suppliers and vendors on extrusion materials, shafts, and braiding

* Thrive in a fast paced, dynamic environment with changing priorities
* Bachelor's degree in Materials Engineering, Plastics Engineering Technology, or a related field

* 5+ years of hands-on extrusion experience, preferably in medical devices or other highly regulated industries

* Strong experience with polymer and material science, including:
Polyurethane, polyolefins, polycarbonate, PET;
Thermoplastic elastomers (TPE), HDPE, PA; PEBAX, nylon, and nylon based copolymers

* Proven experience developing extrusion processes of increasing complexity

* Experience working in regulated environments (FDA regulated medical devices strongly preferred)

* Excellent written and verbal communication skills

* Strong mechanical aptitude and hands-on problem-solving skills

* Strong documentation, organizational, and procedural discipline

* Ability to understand and translate customer requirements into technical solutions

Nice to have:

* Advanced degree (MS or PhD) in Plastics Engineering or Materials Engineering

* Experience with cardiovascular or advanced medical tubing products

* Knowledge of FDA regulations, guidelines, and quality system requirements