Senior Process Engineer
Boston Materials
Billerica, MA, USA
USD 120k-180k / year
Posted on Apr 30, 2026
Boston Materials produces advanced materials with enhanced energy transfer properties using its patented Z-axis Carbon Fiber technology. The Company's products solve critical performance bottlenecks in applications spanning thermal, electrical, and structural use cases. Its breakthrough Liquid Metal ZRT thermal interface material is designed to solve thermal chokepoints that are facing the next generation of AI and HPC silicon. For more information, visit https://www.bomaterials.com/
THE OPPORTUNITY
A career-defining opportunity rarely offers all of the following:
Direct connection to the mission. Gain a clear understanding of the business and see how your work directly shapes outcomes. With no unnecessary layers, silos, or bureaucracy, every team member contributes meaningfully to the company's success and has the responsibility to drive real impact.
Growth beyond a single role. At Boston Materials, you are not defined by your past experience or limited by a job description. Working alongside leading experts in the field, you will take on new challenges, broaden your expertise, develop new capabilities, and take ownership of projects that matter – while contributing to the broader success of the organization.
Work on problems that matter. Help solve some of the most pressing challenges in the Advanced Semiconductor, AI Infrastructure, and Advanced Materials industries. Boston Materials offers a rare combination of purpose, autonomy, and impact. We invite you to join us.
The Role
Boston Materials’ New Product Introduction (NPI) team is looking for an experienced Senior Process Engineer who can turn cutting-edge R&D into reliable, production-ready manufacturing. In this role, you’ll work closely with Engineering and Operations to translate new processes into clear, repeatable procedures that support our next generation of thermal interface materials.
You’ll own the details of process control and data analysis, implement rigorous monitoring to spot patterns, uncover root causes, and push systems to meet high safety, capacity, and yield targets. This work isn’t just about maintaining stability, it’s solving hard problems, removing bottlenecks, and unlocking the keys to scaling production processes to high-volume operations.
If you’re driven by troubleshooting complex systems, validating bold ideas, and building processes that stand up to real-world production, this is the place to do it.
Your Responsibilities
- Design and optimize novel chemical/materials processes for commercial production of advanced materials.
- Deliver key Release-to-Manufacturing milestones and capacity scaling across new manufacturing and quality processes.
- Develop and execute DOE’s that improve understanding of process fundamentals and ultimately lead to increases in process stability, capability, and scale.
- Perform root cause analysis and resolution of assignable cause variation.
- Identify, select, and implement instrumentation, controls, etc. to enable process and material characterization necessary to achieve developmental goals.
- Conceive new process equipment designs or modifications to commercially available equipment to suit process requirements. Lead activities of external vendors or internal counterparts to execute these designs/modifications.
- Assist Operations team in devising and implementing workflow improvements.
- Work with quality engineers to establish quality metrics that assure product form, fit, and function.
- Lead process FMEA for new processes.
- Conspicuously exemplify high standards of safety, organization, communication, and documentation.
- Implement 6S for production equipment and workstations.
- Work effectively in a startup or small company setting. Embrace challenges, adapt to changes, and continuously seek to improve.
Your Skills and Expertise
- Bachelor's or Master’s degree in Chemical Engineering or Materials Science strongly preferred; equivalent experience considered.
- Demonstrated success developing chemical processes, roll-to-roll systems, and other continuous manufacturing workflows.
- Hands-on ability to perform hazard analyses, define engineering controls, and ensure safe operation of complex processes.
- Strong understanding of sensing technologies and data acquisition methods for process monitoring and control.
- Commitment to 6S principles and building clean, organized, and efficient work areas.
- Consistent track record of driving continuous improvement initiatives that raise throughput, quality, and reliability.
- Ability to perform process FMEAs to identify risks, prioritize mitigations, and strengthen process robustness.
- Solid grounding in applied statistics, including capability analysis, control charts, ANOVA, and hypothesis testing.
Summary of Benefits
- Health, Vision & Dental – Boston Materials pays 75% of Health, Vision and Dental Care coverage for employee and dependents
- 4 weeks of supplemental Paid Parental and Family Leave
- Unlimited Paid Time Off
- Holidays: 14 days/year
Boston Materials is an EOE and at the forefront of materials innovation, the key to which is diverse teams with unique backgrounds and experiences. We are committed to employing a diverse workforce with equal employment opportunities regardless of race, color, religion, sex, national origin, age, sexual orientation, gender identity, gender expression, marital status, veteran status, or disability.
Applicants must be currently authorized to work in the US on a full-time basis.
120000 - 180000 USD a year