Product Development Engineer Jobs in Pennsylvania

About the Role:

We are seeking a hands-on Product Development Engineer to lead the development, optimization, and scale-up of advanced ceramic forming technologies for lead zirconate titanate (PZT) piezoelectric ceramics. This role focuses on new product development, ceramic process engineering, materials research, and manufacturing process optimization, with particular emphasis on extrusion, slip casting, ceramic injection molding, and near-net-shape manufacturing. The Product Development Engineer will bridge research and development (R&D), new product introduction (NPI), and production manufacturing to develop scalable processes that improve product quality, dimensional accuracy, material utilization, production yield, and piezoelectric performance.

Responsibilities:

• Lead the development, testing, and optimization of advanced ceramic forming technologies, including extrusion, slip casting, ceramic injection molding (CIM), and near-net-shape manufacturing for complex piezoelectric components.
• Develop and refine ceramic feedstock formulations, binder systems, plasticizers, dispersants, solids loading, rheological properties, mixing procedures, de-airing methods, and forming parameters to improve material consistency and manufacturing efficiency.
• Design and optimize manufacturing tooling, extrusion dies, molds, fixtures, and equipment requirements in collaboration with engineering, production teams, and external suppliers.
• Plan and execute design of experiments (DOE) to establish manufacturing process parameters, evaluate material behavior, optimize dimensional tolerances, reduce defects, and improve product performance.
• Develop and optimize thermal processing methods, including drying, debinding, binder burnout, calcination, sintering, and hot isostatic pressing (HIP), to control ceramic shrinkage, density, microstructure, distortion, and cracking.
• Support ceramic manufacturing operations involving powder synthesis, milling, spray drying, uniaxial pressing, cold isostatic pressing (CIP), green machining, precision machining, cleaning, electroding, plating, poling, aging, and final product testing.
• Perform material characterization and analysis using particle-size analysis, density measurements, rheology testing, dimensional inspection, optical microscopy, scanning electron microscopy (SEM/EDS), and X-ray diffraction (XRD). Evaluate dielectric, ferroelectric, and piezoelectric properties to determine relationships between processing conditions and material performance.
• Manage new product introduction (NPI) and manufacturing scale-up projects, transitioning laboratory-developed ceramic processes into pilot production and full-scale manufacturing. Develop standard operating procedures (SOPs), process specifications, equipment requirements, work instructions, and production qualification documentation.
• Lead process improvement, manufacturing troubleshooting, root cause analysis, and corrective action initiatives addressing cracking, distortion, contamination, dimensional variation, density inconsistencies, and production yield loss. Utilize statistical process control (SPC), process capability analysis, and data-driven engineering techniques.
• Collaborate with R&D, manufacturing, quality assurance, production planning, technical sales, customers, and suppliers to translate product requirements into manufacturable solutions. Prepare technical reports, communicate project milestones, and ensure compliance with safety, environmental, quality, and lead-handling requirements.

Qualifications:

• Bachelor's degree in Ceramic Engineering, Materials Science and Engineering, Chemical Engineering, Mechanical Engineering, or a closely related engineering discipline.
• Hands-on experience in technical ceramics, ceramic materials development, process engineering, or advanced ceramic manufacturing.
• Practical knowledge of at least one advanced ceramic forming process, such as extrusion, slip casting, ceramic injection molding, tape casting, or ceramic additive manufacturing.
• Strong understanding of ceramic powder processing, rheology, binder systems, drying, debinding, sintering, shrinkage control, material properties, and manufacturing defect prevention.
• Experience with ceramic material characterization techniques, including particle-size analysis, density measurements, optical microscopy, scanning electron microscopy (SEM/EDS), X-ray diffraction (XRD), or comparable analytical testing methods.
• Knowledge of experimental design, statistical analysis, process development, manufacturing troubleshooting, root cause analysis, and continuous improvement methodologies.
• Ability to read, interpret, and develop technical drawings, engineering specifications, manufacturing process instructions, and equipment requirements.
• Proficiency with Microsoft Excel, Word, and PowerPoint for engineering documentation, experimental data analysis, technical reporting, and project presentations.
• Strong analytical thinking, hands-on problem-solving abilities, project management skills, and effective written and verbal communication in cross-functional engineering and manufacturing environments.
• Ability to work safely in laboratory, pilot production, and manufacturing settings involving ceramic powders, chemicals, furnaces, forming equipment, and production machinery. Must be able to use appropriate personal protective equipment (PPE) and handle materials weighing up to 50 pounds. U.S. citizenship or permanent resident status is required.

Desired Qualifications:

• Master's degree or Ph.D. in Ceramic Engineering, Materials Science, Chemical Engineering, Mechanical Engineering, or a related technical discipline.
• Three or more years of relevant professional experience in product development engineering, ceramic manufacturing, materials research and development, or manufacturing process engineering.
• Direct experience with lead zirconate titanate (PZT), piezoelectric ceramics, ferroelectric materials, dielectric ceramics, or other functional oxide materials.
• Experience developing and scaling multiple ceramic forming methods, particularly extrusion, slip casting, and ceramic injection molding, including feedstock optimization, tooling development, and advanced manufacturing processes.
• Demonstrated experience transferring ceramic materials or manufacturing processes from laboratory development into pilot-scale or commercial production, including process qualification, equipment selection, and capital equipment justification.
• Familiarity with piezoelectric material testing, dielectric characterization, impedance analysis, electroding, plating, poling, and electrical property evaluation, along with experience using Minitab, CAD software, process simulation, statistical process control (SPC), lean manufacturing, or Six Sigma methodologies.