Senior R&D Thermoplastic Manufacturing Engineer (Startup)

**Job Title: Senior R&D Thermoplastic
Manufacturing Engineer (Startup)Experience:** 2–5 years industry experience (or PhD + relevant research)
Education: Minimum M.S.(PhD strongly preferred)
Department: Advanced Manufacturing / R&D
Reporting To: CTO / VP Engineering / Founder

Position Summary

We are an early-stage aerospace composites
startup developing next-generation thermoplastic composite structures for civil
and defence applications. We seek a highly capable R&D engineer who can
convert cutting-edge materials and manufacturing concepts into scalable
production-ready processes.

This role requires both deep technical
knowledge and strong hands-on execution. The candidate must be comfortable
working in an unstructured startup environment, moving between laboratory
experimentation, process development, tooling design, factory setup, and
customer demonstrations.

Key Responsibilities

• Lead development of novel thermoplastic composite manufacturing

processes from concept to pilot production.

• Build and optimize manufacturing methods including:

• Thermoforming

• Compression molding

• Stamp forming

• Automated layup

• Induction / resistance welding

• Over-molding and hybrid molding

• Design and execute R&D experiments using DOE and

statistical methods.

• Establish process windows for temperature, pressure, dwell, and

cooling cycles.

• Develop methods to reduce defects such as porosity, wrinkles,

incomplete consolidation, and weld failures.

• Work directly with founders to define technology roadmap and IP

strategy.

• Evaluate new materials, suppliers, and equipment.

• Support prototype builds and customer demonstrations.

• Help build internal manufacturing labs, process documentation,

and SOPs.

• Contribute to patent disclosures, technical publications, and

proposal writing.

Requirements

Required Qualifications

• M.S. minimum; PhD preferred in engineering or materials

science.

• 2–5 years of relevant industrial experience, OR PhD with strong

applied research.

• Strong knowledge of thermoplastic composites and polymer

processing.

• Hands-on experience with high-performance polymers such as

PEEK, PEKK, PPS, and PEI.

• Familiarity with composite testing, microscopy, and failure

analysis.

• Strong analytical and experimental mindset.

Ideal Startup Candidate Traits

• Builder mentality; comfortable creating systems from scratch

• Highly hands-on in lab/shop environments

• Comfortable with ambiguity and rapid iteration

• Strong ownership mindset

• Can operate independently with minimal supervision

• Strong communication with customers, investors, and technical

partners

• **Demonstrated ability to build something from zero (lab,

process, prototype, tooling, or pilot line)**