Senior Process Engineer- Materials​/Metallurgy

What we want:

We are seeking a Senior Materials Science Engineer to lead the development, industrialization, and scale-up of Low Pressure Metal Injection Molding (LPMIM) technologies within Advanced Operations & Manufacturing.

This role plays a critical part in enabling next-generation medical device products — translating materials science innovation into scalable, high-volume, cost-optimized, and compliant manufacturing solutions. You will serve as the technical authority for LPMIM materials and processes, driving performance, reliability, and manufacturability from early concept through commercial production.

This is a high-visibility role partnering closely with R&D, Design Engineering, Global Manufacturing, Quality, and external suppliers to build differentiated manufacturing capability.

• Partner with R&D and Design Engineering to evaluate LPMIM feasibility for new components and assemblies.

• Lead Design for Manufacturability (DFM/DFA) reviews, translating product requirements into material, geometry, and process parameters.

• Define material selection strategies, feedstock composition, and downstream processing requirements to meet performance and regulatory standards.

• Develop and optimize LPMIM feed stocks, molding parameters, debinding profiles, and sintering cycles to achieve mechanical, chemical, and dimensional targets.

• Conduct advanced materials characterization (SEM, metallography, DSC/TGA, mechanical testing) to validate process capability and long-term reliability.

• Lead structured root cause investigations and implement sustainable corrective and preventive actions.

• Design and scale robust LPMIM processes for high-volume, cost-efficient production.

• Develop capacity models, cycle time analyses, and network-level scaling strategies.

• Integrate molding, debinding, sintering, and material handling systems into full production cells in partnership with global sites and suppliers.

• Lead mold and tooling strategy for high-volume LPMIM operations, focusing on thermal behavior, wear performance, and repeatability.

• Partner with suppliers through design, fabrication, FAT/SAT, and lifecycle management of tooling and capital equipment.

• Lead process validation activities (IQ/OQ/PQ) in compliance with FDA, ISO 13485, and internal quality systems.

• Drive PFMEA and risk mitigation strategies for material and process-related risks.

• Serve as the LPMIM subject matter expert across Advanced Operations, influencing technical decisions throughout the product lifecycle.

• Support pilot builds, engineering runs, and production ramp-up at global manufacturing sites.

• Champion Lean and Six Sigma initiatives to improve yield, reduce scrap, and optimize material cost.

• Identify and deploy emerging materials and technologies to advance LPMIM capability.

• Bachelor’s degree in Materials Science, Metallurgy, or related field.

• 2+ years of experience in Metal Injection Molding (MIM), powder metallurgy, thermally processed metals manufacturing or related duties.

• Master’s degree in Materials Science or related discipline.

• Demonstrated success scaling processes from prototype to high-volume production.

• Experience in medical device or other regulated, high-precision industries.

• Strong expertise in MIM materials science, sintering behavior, tooling principles, and feedstock design.

• Proficiency in CAD (Solid Works or Creo) and simulation tools (mold flow, thermal analysis).

• Experience with validation protocols, DOE, SPC, and structured problem-solving methodologies.

• Six Sigma Green or Black Belt certification.

• Working knowledge of GD&T (ASME Y14.5).

Health benefits include:
Medical and prescription drug insurance, dental insurance, vision insurance, critical illness insurance, accident insurance, hospital indemnity insurance, personalized healthcare support, wellbeing program and tobacco cessation program. Financial benefits include:
Health Savings Account (HSA), Flexible Spending Accounts (FSAs), 401(k) plan, Employee Stock Purchase Plan (ESPP), basic life and AD&D insurance, and short-term disability insurance. Stryker offers innovative products and services in Med Surg, Neurotechnology, Orthopaedics and Spine that help improve patient and healthcare outcomes. Alongside its customers around the world, Stryker impacts more than 150 million patients annually. Depending on customer requirements employees and new hires in sales and field roles that require access to customer accounts as a function of the job may be required to obtain various vaccinations as an essential function of their role.