Senior Level Process Development Engineer Jobs
Senior level process development engineer jobs place experienced engineers in ownership of critical processes, from defining technical strategy to leading cross-functional teams and delivering scalable manufacturing solutions. Openings are concentrated across Biotechnology & Pharmaceuticals, Manufacturing, and Science & Research, with 0% offering remote or hybrid arrangements, and employers like INEOS, Insmed, and Genezen hiring at this level now.
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Job Title: Principal Process Development Engineer, Powder Scale-Up
Job Summary:
Alsym Energy Inc. is seeking a hard-working, self-driven and highly technical Principal Process Development Engineer to lead the scale-up of active materials powders, and associated particle engineering processes, for next-generation energy storage systems. In this role, the candidate will serve as the senior technical authority for maturing powder production processes from lab-through to pilot-scale and toward volume manufacturing, working closely with a team of scientists and engineers to deliver products satisfying strict performance requirements. This is a hands-on leadership role for someone who has built a career scaling inorganic electroactive-powders in an industrial setting and wants to shape the scale-up strategy for a rapidly growing energy storage company.
Industry Background:
Energy storage is one of the fastest-growing sectors in the global energy economy, with annual stationary storage capacity additions projected to grow 23% per year from 2025 to 2035, driven by surging electricity demand from electrification, data centers, and AI infrastructure. Alsym Energy is the leading developer of non-flammable, high-performance, low-cost sodium-ion batteries for AI data centers, utilities, commercial real estate and anywhere else energy storage is needed.
Key Qualifications:
- BS, MS, or PhD in Chemical Engineering, Materials Science and Engineering, Chemistry, or a related field.
- Minimum 15+ years of industry experience working with inorganic powders, with a demonstrated track record of scaling one or more powder synthesis processes from the precursor to the final product spanning research through to full-scale production.
- Proven ability to lead powder and particle scale-up efforts end-to-end, including equipment selection, process design, technology transfer, and pilot-line or manufacturing start-up.
- Deep, hands-on expertise with synthesis techniques such as spray drying, co-precipitation, or hydrothermal, including formulation and process optimization to meet particle size or morphological design and performance specifications.
- Significant hands-on experience with powder processing methods including, calcination, sintering, carbonization, milling, and sieving.
- Strong fundamental understanding of colloid/surface chemistry, with experience optimizing dispersion and surface functionalization strategies.
- Experience establishing control plans and quality control/quality assurance programs, and leading root-cause and FMEA-driven troubleshooting across process and manufacturing teams.
- Experience in batteries, catalysts, inorganic pigments, ceramics, or specialty materials is highly desired; experience in GMP or other regulated environments and technology transfer to CMOs or pilot facilities is a plus.
Roles & Responsibilities:
- Serve as the principal technical leader for particle engineering and cathode active materials powder scale-up, developing and executing the strategy for optimizing and controlling properties such as particle size distribution, surface area, morphology, tap density and surface chemistry.
- Lead the design, optimization, and scale-up of particle engineering processes such as spray drying, milling, calcination, sintering, and carbonization—from lab-scale research through pilot-line and into full-scale manufacturing.
- Serve as technical liaison between R&D, and external manufacturing partners, contributing to design of experiments, process documentation, and technology transfer.
- Partner with process development engineers and scientists to sustain and continuously improve existing and new particle engineering processes, including operations and material traceability across the line.
- Institute and own control plans and quality control/quality assurance programs to ensure consistent particle and electrode performance across batches and scales; collaborate across groups to diagnose and troubleshoot performance issues and conduct FMEA/RCA as required.
- Direct particle characterization efforts using techniques such as SEM, EDX, XRD, and particle size analyzers, and coordinate external testing as needed.
- Plan and coordinate experiments between synthesis and prototyping teams in order to establish key relationships between powder properties and electrode and cell level properties and performance characteristics.
- Evaluate the technical capabilities, equipment, and quality systems of prospective contract manufacturers and toll processors to assess fit for scale-up.
- Mentor and provide technical guidance to junior and mid-level engineers and scientists, and contribute to long-term strategic planning for the powder engineering and scale-up roadmap.
Why Join Us?
At Alsym, we believe in equitable compensation and a healthy work-life balance. Beyond a competitive salary, we offer a benefits package designed to support you both inside and outside the office.
Perks & Lifestyle
- Prime Location: We are within easy walking distance of the train station.
- Commuter Friendly: Enjoy the convenience of free on-site parking.
- Health & Wellness: Stay active with access to our free on-site gym.
- Friday Fuel: We provide free lunch delivery every Friday to celebrate the end of the work week together.
Comprehensive Benefits
- Health & Dental: Premium insurance coverage through Blue Cross Blue Shield.
- Financial Future: Every employee is eligible for 401k plans and stock options.
- Time to Recharge: A flexible Paid Time Off (PTO) program to help you find your balance.
- Family & Security: Full eligibility for PFML (Paid Family and Medical Leave).
Our Commitment to You
We maintain a firm Anti-Harassment Policy that includes robust Diversity, Inclusion, Equity, and Gender Protections. We are an equal opportunity employer and value diversity at our company. We do not discriminate on the basis of race, religion, color, national origin, gender, sexual orientation, age, marital status, veteran status, or disability status.
Note: A full, detailed listing of all benefits will be provided following a formal offer of employment.
Job Title: Principal Process Development Engineer, Powder Scale-Up
Job Summary:
Alsym Energy Inc. is seeking a hard-working, self-driven and highly technical Principal Process Development Engineer to lead the scale-up of active materials powders, and associated particle engineering processes, for next-generation energy storage systems. In this role, the candidate will serve as the senior technical authority for maturing powder production processes from lab-through to pilot-scale and toward volume manufacturing, working closely with a team of scientists and engineers to deliver products satisfying strict performance requirements. This is a hands-on leadership role for someone who has built a career scaling inorganic electroactive-powders in an industrial setting and wants to shape the scale-up strategy for a rapidly growing energy storage company.
Industry Background:
Energy storage is one of the fastest-growing sectors in the global energy economy, with annual stationary storage capacity additions projected to grow 23% per year from 2025 to 2035, driven by surging electricity demand from electrification, data centers, and AI infrastructure. Alsym Energy is the leading developer of non-flammable, high-performance, low-cost sodium-ion batteries for AI data centers, utilities, commercial real estate and anywhere else energy storage is needed.
Key Qualifications:
- BS, MS, or PhD in Chemical Engineering, Materials Science and Engineering, Chemistry, or a related field.
- Minimum 15+ years of industry experience working with inorganic powders, with a demonstrated track record of scaling one or more powder synthesis processes from the precursor to the final product spanning research through to full-scale production.
- Proven ability to lead powder and particle scale-up efforts end-to-end, including equipment selection, process design, technology transfer, and pilot-line or manufacturing start-up.
- Deep, hands-on expertise with synthesis techniques such as spray drying, co-precipitation, or hydrothermal, including formulation and process optimization to meet particle size or morphological design and performance specifications.
- Significant hands-on experience with powder processing methods including, calcination, sintering, carbonization, milling, and sieving.
- Strong fundamental understanding of colloid/surface chemistry, with experience optimizing dispersion and surface functionalization strategies.
- Experience establishing control plans and quality control/quality assurance programs, and leading root-cause and FMEA-driven troubleshooting across process and manufacturing teams.
- Experience in batteries, catalysts, inorganic pigments, ceramics, or specialty materials is highly desired; experience in GMP or other regulated environments and technology transfer to CMOs or pilot facilities is a plus.
Roles & Responsibilities:
- Serve as the principal technical leader for particle engineering and cathode active materials powder scale-up, developing and executing the strategy for optimizing and controlling properties such as particle size distribution, surface area, morphology, tap density and surface chemistry.
- Lead the design, optimization, and scale-up of particle engineering processes such as spray drying, milling, calcination, sintering, and carbonization—from lab-scale research through pilot-line and into full-scale manufacturing.
- Serve as technical liaison between R&D, and external manufacturing partners, contributing to design of experiments, process documentation, and technology transfer.
- Partner with process development engineers and scientists to sustain and continuously improve existing and new particle engineering processes, including operations and material traceability across the line.
- Institute and own control plans and quality control/quality assurance programs to ensure consistent particle and electrode performance across batches and scales; collaborate across groups to diagnose and troubleshoot performance issues and conduct FMEA/RCA as required.
- Direct particle characterization efforts using techniques such as SEM, EDX, XRD, and particle size analyzers, and coordinate external testing as needed.
- Plan and coordinate experiments between synthesis and prototyping teams in order to establish key relationships between powder properties and electrode and cell level properties and performance characteristics.
- Evaluate the technical capabilities, equipment, and quality systems of prospective contract manufacturers and toll processors to assess fit for scale-up.
- Mentor and provide technical guidance to junior and mid-level engineers and scientists, and contribute to long-term strategic planning for the powder engineering and scale-up roadmap.
Why Join Us?
At Alsym, we believe in equitable compensation and a healthy work-life balance. Beyond a competitive salary, we offer a benefits package designed to support you both inside and outside the office.
Perks & Lifestyle
- Prime Location: We are within easy walking distance of the train station.
- Commuter Friendly: Enjoy the convenience of free on-site parking.
- Health & Wellness: Stay active with access to our free on-site gym.
- Friday Fuel: We provide free lunch delivery every Friday to celebrate the end of the work week together.
Comprehensive Benefits
- Health & Dental: Premium insurance coverage through Blue Cross Blue Shield.
- Financial Future: Every employee is eligible for 401k plans and stock options.
- Time to Recharge: A flexible Paid Time Off (PTO) program to help you find your balance.
- Family & Security: Full eligibility for PFML (Paid Family and Medical Leave).
Our Commitment to You
We maintain a firm Anti-Harassment Policy that includes robust Diversity, Inclusion, Equity, and Gender Protections. We are an equal opportunity employer and value diversity at our company. We do not discriminate on the basis of race, religion, color, national origin, gender, sexual orientation, age, marital status, veteran status, or disability status.
Note: A full, detailed listing of all benefits will be provided following a formal offer of employment.
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Senior Level Process Development Engineer Jobs: Frequently Asked Questions
How do I get a senior level process development engineer job?
Employers hiring at the senior level look for engineers who can own a process improvement initiative from concept through validation without close supervision. Demonstrating experience leading cross-functional projects, mentoring junior engineers, and translating technical findings into business decisions gives candidates a clear edge. A strong portfolio of process characterization, scale-up work, or yield improvement outcomes makes the case concrete.
Which companies hire senior level process development engineers?
Companies hiring senior level process development engineers right now include INEOS, Insmed, and Genezen, based on current listings on Migrate Mate as of November 2026. Hiring at this level is driven by pharmaceutical manufacturers, semiconductor and electronics firms, specialty chemical producers, and advanced medical device companies scaling new production processes.
Are there remote senior level process development engineer jobs?
Yes, though on-site roles remain common given the lab and manufacturing floor requirements of most process development work. About 0% of senior level process development engineer openings are remote or hybrid as of November 2026, with hybrid arrangements most prevalent at companies that separate R&D analysis work from physical process validation.
What makes a process development engineer role senior level?
Senior level roles are defined by scope and ownership rather than task execution. Engineers at this stage lead process design or optimization programs, make independent technical decisions, represent their function in cross-departmental planning, and mentor mid-level or junior colleagues. Employers expect demonstrated ability to resolve novel process failures, author technical documentation for regulatory submissions, and drive continuous improvement with measurable outcomes.
Which industries hire the most senior level process development engineers?
Senior Level process development engineer roles concentrate in Biotechnology & Pharmaceuticals, Manufacturing, and Science & Research, based on current listings on Migrate Mate as of November 2026. These sectors drive hiring at this level because they depend on rigorous process control, scale-up from pilot to production, and the regulatory compliance demands that require experienced engineers to own technical decisions.