Sr. Materials Engineer, R&D Core Materials

Sr. Materials Engineer, R&D Core Materials

Align Technology seeks a Senior Materials Engineer with deep expertise in polymer science, sustainability, material compatibility, and medical device packaging. You will lead complex, cross‑functional projects spanning orthodontic accessory and ancillary product compatibility, recycled materials innovation, and advanced packaging development.

• Lead material selections and studies for orthodontic accessory and ancillary products to ensure safety, functionality with Invisalign orthodontic appliances, and packaging.
• Develop circular‑material technologies by transforming recycled polymers into high‑performance, qualified applications.
• Design, evaluate, and optimize medical and consumer packaging for performance, manufacturability, and sustainability in accordance with ISO 11607 and ASTM/ISTA standards.
• Perform standard and customized polymer characterization (thermal, mechanical, rheological, spectroscopic) and long‑term reliability evaluations.
• Define and approve material specifications; author validation protocols and reports per Design Control and QMS requirements.
• Collaborate with internal teams and external partners to evaluate, qualify, and scale sustainable materials and packaging solutions worldwide.
• Support chemical‑compliance and biocompatibility evaluations to ensure regulatory readiness and provide data for product filings.
• Translate complex test results into clear technical reports, risk assessments, and strategic recommendations that guide product and business decisions.
• Mentor and coach engineers and technicians to strengthen experimental design, data integrity, and sustainability best practices.

• MS or PhD in Polymer Science, Materials Science, Chemistry, Chemical Engineering, or related discipline.
• 8+ years of R&D experience involving polymers, packaging, or medical devices.
• Proven expertise in polymer characterization, structure–property analysis, and material compatibility evaluation.
• Strong background in sustainability and recycled materials development, including processing, evaluation, and qualification for value‑added applications.
• Hands‑on experience in packaging materials design, development, and validation for medical or consumer products.
• Excellent technical communication and cross‑functional collaboration skills.
• Strong analytical thinking and ability to translate data into practical engineering recommendations.
• Demonstrated ability to manage multiple projects and influence cross‑functional stakeholders.

• Experience evaluating material interactions for chemical and functional compatibility with medical devices and packaging systems.
• Knowledge of environmental, chemical, and packaging compliance standards (REACH, RoHS, Prop 65, TSCA, ISO 10993, ISO 11607).
• Familiarity with sustainable packaging materials, validation methods, and ASTM/ISTA test standards.
• Working knowledge of design control, risk management, and validation processes in accordance with ISO 13485 and FDA QSR requirements.

Align offers a comprehensive benefits package, including medical, dental, and vision coverage; 401(k) with company match; paid vacation; paid parental leave; and other employee assistance programs. Detailed information is available upon request.

Align Technology is an equal opportunity employer. We are committed to providing equal employment opportunities in all our practices, without regard to race, color, religion, sex, national origin, ancestry, marital status, protected veteran status, age, disability, sexual orientation, gender identity or expression, or any other legally protected category.