NPI Engineer

Zotefoams plc is a world leader in cellular material technology, with facilities in Croydon, UK;
Kentucky and Oklahoma, USA;
Brzeg, Poland; and Jiangsu Province, China (T-FIT).

We produce lightweight foams for a wide range of markets including sports and leisure, aviation, automotive, and healthcare. Zotefoams also owns and licenses patented technology and supplies advanced insulation systems.

The Company is on a strong growth trajectory, with significant revenue and profitability increases in recent years and ambitious plans for the future.

We are seeking an NPI Engineer to join our team in Croydon. This role will focus on introducing new foam products and manufacturing processes from development through to full scale production.

The successful candidate will ensure that new foam formulations, tooling, and production processes are robust, repeatable, cost effective, and meet quality, performance, and safety requirements. Working closely with cross functional teams, the NPI Engineer will play a key role in supporting successful product launches and ensuring manufacturing readiness.

• Lead NPI activities for new foam products including trials, pilot runs, and production ramp up.

• Manage project timelines, risks, and deliverables for new product launches.

• Coordinate scale up from laboratory or prototype foam trials into full production.

• Develop and optimise foam manufacturing processes and any required subprocesses.

• Define and validate key process parameters such as mix ratios, temperatures, pressures, cure times, densities, and cycle times.

• Support formulation changes to meet performance, cost, and sustainability targets.

• Specify and validate any equipment requirements.

• Create new process flows, work instructions, and standard operating procedures where required.

• Conduct PFMEA, process capability studies, and line trials.

• Ensure product master data is accurate and ready for launch.

• Work closely with the Quality team to define inspection methods and acceptance criteria.

• Investigate defects through root cause analysis and implement corrective actions.

• Collaborate with internal teams, supply chain partners, and external customers to deliver successful product launch plans.

• Support customer trials, approvals, and technical documentation where required.

• Bachelor’s degree in Chemical, Mechanical, Manufacturing, or Materials Engineering, or equivalent experience.

• Experience in NPI, Process Engineering, or Manufacturing Engineering within the foam or polymer industry.

• Hands on experience with foam manufacturing processes.

• Strong understanding of process control, troubleshooting, and production scale up.

• Experience using PFMEA, SPC, and root cause analysis tools.

A proactive and collaborative engineer who enjoys working across teams to bring new products successfully into production.

Someone who takes ownership of projects, demonstrates strong problem solving skills, and is comfortable working in a dynamic manufacturing environment.

A team player who can balance technical rigour with practical delivery and who is motivated to support continuous improvement and innovation.

At Zotefoams, we believe in fostering a supportive and innovative environment where everybody can thrive. By joining us, you will be part of a dynamic team that values collaboration, continuous improvement, and opportunities for professional growth and development.

Courage – The courage to take bold action to ensure that we succeed in tackling our challenges and opportunities.

Impact – Dedicated to making a significant and positive impact in everything we do.

Respect – Cultivate a respectful and inclusive environment where everyone is valued and collaboration is encouraged.

Zotefoams is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.