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Aspen Aerogels

Senior Process Engineer

East Providence, RI · On-site

$130K - $150K/yr

The Company's aerogel technology enables its customers and partners to achieve their own objectives around the global megatrends of resource efficiency, e-mobility, and clean energy. Aspen's PyroThin ...

Aspen Aerogels

R&D Engineer I

Northborough, MA · On-site

$90K - $105K/yr

The Company's aerogel technology enables its customers and partners to achieve their own objectives around the global megatrends of resource efficiency, e-mobility, and clean energy. Aspen's PyroThin ...

Aspen Aerogels

Product Marketing Manager

Northborough, MA · On-site

$140K - $160K/yr

The Company's aerogel technology enables its customers and partners to achieve their own objectives around the global megatrends of resource efficiency, e-mobility, and clean energy. Aspen's PyroThin ...

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How much do aerogel jobs pay per hour?

As of Aug 23, 2026, the average hourly pay for aerogel in the United States is $18.29, according to ZipRecruiter salary data. Most workers in this role earn between $16.35 and $21.15 per hour, depending on experience, location, and employer.

What is an aerogel?

Aerogels are a class of ultra-lightweight, porous materials derived from a gel, in which the liquid component of the gel is replaced with a gas without collapsing the gel structure. They are known for their extremely low density, high surface area, and remarkable thermal insulation properties. Aerogels are used in a variety of applications, including insulation, filtration, and even in space missions due to their unique physical and chemical characteristics.

What are the key skills and qualifications needed to thrive as an aerogel engineer, and why are they important?

To thrive as an Aerogel Engineer, you need a strong background in materials science, chemical engineering, and a relevant degree, such as a BS or MS in chemical, materials, or mechanical engineering. Familiarity with laboratory synthesis techniques, analytical instruments (like SEM, TEM, and spectroscopy), and knowledge of safety protocols are typically required. Strong problem-solving abilities, attention to detail, and effective teamwork and communication skills help professionals excel in research and development settings. These skills are vital to ensuring innovation, safe production, and the successful application of aerogel materials across various industries.

What are some common challenges faced by professionals working in aerogel research and development?

Professionals in aerogel R&D often encounter challenges related to the material's fragility and complex manufacturing processes. Achieving consistent quality and scalability for commercial applications can be difficult, requiring close attention to process controls and safety protocols. Collaboration with multidisciplinary teams—including chemists, engineers, and product designers—is essential to overcome these hurdles and develop innovative uses for aerogels in industries such as construction, aerospace, and energy. Staying current with technological advancements and regulations is also important for continued success in this field.
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Infographic showing various Aerogel job openings in the United States as of August 2026, with employment types broken down into 100% Full Time. Highlights an 100% In-person job distribution, with an average salary of $38,034 per year, or $18.3 per hour.

Senior Process Engineer

Aspen Aerogels

East Providence, RI • On-site

$130K - $150K/yr

Full-time

Medical, Dental, Vision, Life, Retirement, PTO

Re-posted 4 days ago

Aspen Aerogels rating

6.7

Company rating: 6.7 out of 10

Based on 5 frontline employees who took The Breakroom Quiz

Job description

What we do-
Aspen is a technology leader in sustainability and electrification solutions. The Company's aerogel technology enables its customers and partners to achieve their own objectives around the global megatrends of resource efficiency, e-mobility, and clean energy. Aspen's PyroThin® products enable solutions to thermal runaway challenges within the electric vehicle ("EV") market. The Company's Cryogel® and Pyrogel® products are valued by the world's largest energy infrastructure companies. Aspen's strategy is to partner with world-class industry leaders to leverage its Aerogel Technology Platform® into additional high-value markets. Aspen is headquartered in Northborough, Mass.
What we value-
At Aspen, our values reflect who we are and how we work both with each other and our customers, suppliers, and communities. They shape our interactions, guide our decisions, and inspire us to bring our best. Whether collaborating internally or externally, our values drive us to make a meaningful impact within Aspen and in all our relationships.
Aspen's CORE Values
We Do the Right Thing
We are Problem Solvers
We are Allies
We Drive Forward
What you will do-
The Sr. Process Engineer will report to the Senior Manager, Production Support. The Engineer will be responsible for driving functional excellence in the area of aerogel manufacturing by providing strategic, technical and new process design and development support for the R&D and manufacturing teams. Under the direction of the Senior Manager, the Engineer will lead the design of future aerogel manufacturing methods and process technologies. The Engineer will also assist with optimizing production of existing products, trialing and scaling up of new products.
How will you do it-
  • Lead technically transformational process change in manufacturing partnering with R&D to develop next generation manufacturing of aerogel composites.
  • Partner with R&D and Plant Engineering to identify, develop and execute new product and new process improvements in the areas of safety, production capacity, yield and cost reduction.
  • Partner with R&D to interpret product design requirements to determine feasibility, process steps required, and cost to manufacture.
  • Transfer new technologies, products, and manufacturing processes into the Company.
  • Establish project goals and priorities by collaborating with Marketing and Operations.
  • Support the successful introduction of new products and processes. Lead and/or execute the experimental work required to support scale up activities and develop a robust commercial scale aerogel manufacturing process from small-scale laboratory data.
  • Analyze process and quality data to improve/troubleshoot the aerogel manufacturing process
  • Partner with R&D, Plant Engineering and Manufacturing to support trial manufacturing runs.
  • Coordinate and/or lead troubleshooting of aerogel manufacturing processes to determine root cause of failure modes.
  • Develop and implement corrective actions to mitigate failure modes
  • Provide technical guidance, coaching and training to Plant Engineering and Manufacturing.
  • Lead or support project teams through developmental phases of engineering projects related to process equipment including conceptual design of both process and equipment. Transfer design requirements to Plant Engineering for detailed design, equipment procurement, construction, installation, start up, commissioning, validation, and qualification of facilities and/or equipment.
  • Build upon lab and trial generated best practices to establish and implement full scale standards, documentation and procedures for all new and existing products to ensure manufacturing capabilities.
  • Adopt and follow Aspen's core values of Safety, Quality, Integrity, Teamwork, Customer and Innovation on both a personal and professional level.

Why you are right for the job-
  • Minimum 5+ years' experience in process design and development (process engineering, technology evaluation and deployment, unit operation).
  • BSME or BSChE is required, with appropriate experience in a manufacturing environment, preferably in a Chemical Processing operation.
  • Broad knowledge of chemical process development, preferably with a focus on silica synthesis and modification.
  • Alternatively, a board knowledge of coating, casting, web handling and/or oven drying operations is required.
  • Experience with pilot and high-volume manufacturing operations, and the process of transitioning new products/processes from lab to pilot and full commercial manufacturing.
  • Hands on experience with analytical method development.
  • Hands on lab or pilot plant experience running experiments
  • History of working in a manufacturing operations environment.
  • Experience with research and analytic techniques. Ability to apply statistical analysis and/or practical experience to make sound conclusions and use to optimize process development activities.
  • Ability and willingness to lead and do work.
  • Innate intellectual curiosity.
  • Predisposed to leverage analytic reason, creativity, and judgment.
  • Well-developed influencing skills - ability to inspire confidence and drive consensus.
  • Ability to handle complex matters across multiple initiatives.
  • Intellectual agility to deal effectively with strategic issues and operational details.
  • Ability to effectively influence and motivate external and internal stakeholders.

What to expect-
Physical Demands and Work Environment:
  • Frequently required to stand
  • Occasionally required to walk
  • Frequently required to sit
  • Frequently required to utilize hand and finger dexterity
  • Occasionally required to climb, balance, bend, stoop, kneel or crawl
  • Frequently works near moving mechanical parts
  • Frequently works around fumes, airborne particles, or toxic chemicals
  • Occasionally exposed to extreme heat or cold (non-weather)
  • While performing the duties of this job, the noise level in the work environment is usually moderate
  • The Engineer must occasionally lift and/or move more than 10 pounds.

The above is intended to describe the general content of and requirements for the performance of this job. It is not to be construed as an exhaustive statement of duties, responsibilities or physical requirements. Nothing in this job description restricts management's right to assign or reassign duties and responsibilities to this job at any time. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
PERKS OF JOINING OUR TEAM!
Aspen is committed to offering a comprehensive benefits package, a positive and productive work environment, encouraged work/life and family balance, and opportunities for growth and development, in a culture that is focused on inclusion, sustainability, and working together to solve the world's toughest challenges.
Aspen is proud to offer a competitive benefits package including Medical, Dental, Vision, Tuition Reimbursement, Paid Holidays, Sick Time, and PTO. In addition, we also offer 401k Employer Match, Life and Disability Insurance, and other benefits.
Expected Compensation: Between $130,000 and $150,000 USD/year based on experience.
Aspen Aerogels, Inc. is committed to working with and providing reasonable accommodations to individuals with disabilities. If you need a reasonable accommodation because of a disability for any part of the employment process, please send an e-mail to abuttitta@aerogel.com or call and leave a voice message at (508) 466-3111 and let us know the nature of your request and your contact information and we will return your message.
For Our Rhode Island Applicants:Aspen Aerogels, Inc. is an equal opportunity employer. We evaluate qualified applicants without regard to race, color, age, religion, sex, sexual orientation, gender identity, national origin, disability, veteran status, and other legally protected characteristics. The East Providence, RI facility of Aspen Aerogels is subject to Title 28, Chapter 29-6.2 of Rhode Island General Laws, which governs Worker's Compensation.
Equal Opportunity Employer
This employer is required to notify all applicants of their rights pursuant to federal employment laws. For further information, please review the Know Your Rights notice from the Department of Labor.

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