Align Technology
Overview
Sr. 3D Process Engineer role at Align Technology — in-person in San Jose, CA. This position involves hands-on in-lab research and development focused on advancing additive manufacturing process control. The successful candidate will lead targeted R&D initiatives to solve fundamental process problems, serve as a subject matter expert in additive manufacturing, and collaborate with cross-functional teams to support regulatory submissions, process validation, and technology transfer activities. Responsibilities
Independently operate new additive manufacturing equipment and post-processing equipment. Perform material and product testing using standard and non-standard material testing equipment. Collect, maintain and organize data in accordance with internal standards and quality requirements. Participate in, and lead select weekly and bi-weekly technical meetings with cross-functional groups. Present data, findings, and ideas to process and cross-functional teams on a weekly basis. Use statistical tools to analyze, interpret, and present experiment results. Write, maintain, and transfer work instructions to manufacturing teams. Write, maintain and support protocols for process and equipment qualifications and process transfer. Write work instructions for core Process R&D activities. Collaborate with cross-functional teams to support major project milestones and receive support as needed. Serve as SME for design for additive manufacturing (DFAM) to support printing and post-process development. Operate, collect and analyze data from polymer characterization equipment to support fundamental research in process-structure-property explorations. Apply process-structure-property insights to tune processes for desired performance and accuracy metrics. Collect, process and analyze data from advanced metrology techniques (CT, CMM, etc.). Analyze orthodontic performance data to explore relationships between process and performance. Lead experimental design, setup and execution to study process-structure-property relationships for polymer AM systems. Lead and delegate tasks to junior team members and technicians supporting R&D activities. Develop, evaluate and support prototyping of equipment, jigs, fixtures and tools for internal manufacturing or with external support. Maintain vendor relationships; participate in design reviews and release of custom equipment. Develop metrics to explore the end-to-end pilot manufacturing process capability for R&D products. Lead development of acceptance metrics, process performance criteria, and in-process monitoring criteria. Lead test method development and validation; plan, execute, and document experiment results for regulatory submissions. Serve as SME for internal and external audits related to process development and optimization. Define requirements for manufacturing software (support generation, slicing, layout, etc.) and liaise for software development, prototyping and testing plans. Support calibration, safety programs, and cross-functional onboarding of junior engineers. Work in a fast-paced environment and meet critical deadlines; problem-solve with attention to detail; coach and mentor peers and junior engineers. Qualifications
MS degree in mechanical or biomedical engineering (or related fields) with 6-8 years of direct 3D printing experience related to SLA/resin-based systems or printed medical devices. PhD degree in mechanical or relevant interdisciplinary field with 3-5 years of direct focus on process or post-process development for photopolymer AM systems (AM experience in medical devices is a bonus). Demonstrable expertise in statistical analysis and design of experiments. Strong independent research and troubleshooting capabilities. Experience handling chemicals such as isopropyl alcohol, photopolymers, cleaning agents. Comfort with risk-based decision making for ambiguous problem statements. Excellent technical communication skills (writing and presentation). Strong mathematical ability to support physical process modeling using experimental data. Experience with imaging instruments (CT scanners, surface profilers, digital microscopes) and related data analysis. Collaborative experience with multidisciplinary teams. Nice To Have
Practical coding experience in Python or similar languages. Experience with end-to-end development of printing or post-process parameters for a specific application or material. Experience collaborating with polymer design/engineering groups. Experience developing process control metrics and process capability. Experience with AM tools (SolidWorks, slicers, toolpath generation software). Experience building/operating custom 3D printers, material testing, or post-processing equipment. Experience with 3D printed medical or biomechanical devices. Pay Transparency
If provided, base salary ranges align with Align's pay practices; actual placement depends on skills and experience, with adjustments for location and total compensation. This section may vary by location. Equal Opportunity
Align Technology is an equal opportunity employer. We are committed to providing equal employment opportunities 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. Applicants must be legally authorized to work in the country of application; employment eligibility will be verified as a condition of hire.
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Sr. 3D Process Engineer role at Align Technology — in-person in San Jose, CA. This position involves hands-on in-lab research and development focused on advancing additive manufacturing process control. The successful candidate will lead targeted R&D initiatives to solve fundamental process problems, serve as a subject matter expert in additive manufacturing, and collaborate with cross-functional teams to support regulatory submissions, process validation, and technology transfer activities. Responsibilities
Independently operate new additive manufacturing equipment and post-processing equipment. Perform material and product testing using standard and non-standard material testing equipment. Collect, maintain and organize data in accordance with internal standards and quality requirements. Participate in, and lead select weekly and bi-weekly technical meetings with cross-functional groups. Present data, findings, and ideas to process and cross-functional teams on a weekly basis. Use statistical tools to analyze, interpret, and present experiment results. Write, maintain, and transfer work instructions to manufacturing teams. Write, maintain and support protocols for process and equipment qualifications and process transfer. Write work instructions for core Process R&D activities. Collaborate with cross-functional teams to support major project milestones and receive support as needed. Serve as SME for design for additive manufacturing (DFAM) to support printing and post-process development. Operate, collect and analyze data from polymer characterization equipment to support fundamental research in process-structure-property explorations. Apply process-structure-property insights to tune processes for desired performance and accuracy metrics. Collect, process and analyze data from advanced metrology techniques (CT, CMM, etc.). Analyze orthodontic performance data to explore relationships between process and performance. Lead experimental design, setup and execution to study process-structure-property relationships for polymer AM systems. Lead and delegate tasks to junior team members and technicians supporting R&D activities. Develop, evaluate and support prototyping of equipment, jigs, fixtures and tools for internal manufacturing or with external support. Maintain vendor relationships; participate in design reviews and release of custom equipment. Develop metrics to explore the end-to-end pilot manufacturing process capability for R&D products. Lead development of acceptance metrics, process performance criteria, and in-process monitoring criteria. Lead test method development and validation; plan, execute, and document experiment results for regulatory submissions. Serve as SME for internal and external audits related to process development and optimization. Define requirements for manufacturing software (support generation, slicing, layout, etc.) and liaise for software development, prototyping and testing plans. Support calibration, safety programs, and cross-functional onboarding of junior engineers. Work in a fast-paced environment and meet critical deadlines; problem-solve with attention to detail; coach and mentor peers and junior engineers. Qualifications
MS degree in mechanical or biomedical engineering (or related fields) with 6-8 years of direct 3D printing experience related to SLA/resin-based systems or printed medical devices. PhD degree in mechanical or relevant interdisciplinary field with 3-5 years of direct focus on process or post-process development for photopolymer AM systems (AM experience in medical devices is a bonus). Demonstrable expertise in statistical analysis and design of experiments. Strong independent research and troubleshooting capabilities. Experience handling chemicals such as isopropyl alcohol, photopolymers, cleaning agents. Comfort with risk-based decision making for ambiguous problem statements. Excellent technical communication skills (writing and presentation). Strong mathematical ability to support physical process modeling using experimental data. Experience with imaging instruments (CT scanners, surface profilers, digital microscopes) and related data analysis. Collaborative experience with multidisciplinary teams. Nice To Have
Practical coding experience in Python or similar languages. Experience with end-to-end development of printing or post-process parameters for a specific application or material. Experience collaborating with polymer design/engineering groups. Experience developing process control metrics and process capability. Experience with AM tools (SolidWorks, slicers, toolpath generation software). Experience building/operating custom 3D printers, material testing, or post-processing equipment. Experience with 3D printed medical or biomechanical devices. Pay Transparency
If provided, base salary ranges align with Align's pay practices; actual placement depends on skills and experience, with adjustments for location and total compensation. This section may vary by location. Equal Opportunity
Align Technology is an equal opportunity employer. We are committed to providing equal employment opportunities 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. Applicants must be legally authorized to work in the country of application; employment eligibility will be verified as a condition of hire.
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