Film Extrusion Product Development Engineer Jobs

Job Location: PPC - Pleasant Prairie - Pleasant Prairie, WI 53158

Position Type: Full Time

DuPont™ Spectrum™ Healthcare Solutions is seeking a New Product Development Engineer – Medical Films & Flexibles Packaging to drive advanced packaging design (films & conversion) & process development for critical healthcare and medical device applications. This technical role offers the opportunity to lead high-impact new product and process development programs from concept through commercialization within a world-class R&D and manufacturing environment. (Location – Pleasant Prairie, WI)

• Flexibles Packaging New Product Design & Development: Ideate and develop new medical-grade films and flexible packaging form factors tailored for healthcare applications such as medical devices. Translate customer and application requirements into clear design specifications and structure–property-process hypotheses to optimize performance requirements such as barrier properties, mechanical strength, and compatibility with sterilization methods. Lead prototype development, process development, testing of films (multi-layer), laminates, and form factors (e.g. pouches, header bags, conversion films) that ensure sterile barrier integrity and durability for medical device packaging.
• Flexibles Packaging & Conversion Process Development: Develop and optimize polymer film extrusion (blown film) and packaging conversion processes (e.g. film casting, slitting, pouch forming, sealing). Scale up new products from prototyping concepts through pilot trials to manufacturing, ensuring processes are robust, efficient, and capable of high-quality output. Collaborate with manufacturing engineers on process scale-up and technology transfer to establish process parameters, standard operating, and procedures Troubleshoot complex process issues using root cause analysis, and implement corrective and preventive actions to continuously improve yield, reliability, and product quality.
• Project Management & Risk Mitigation: Lead and drive cross-functional new product development project teams through a structured stage-gate development process, from concept to commercial launch. Develop and manage project plans defining scope, timeline, resource needs, and critical milestones. Proactively identify and mitigate risks (technical, regulatory, or timeline) using risk management practices (e.g., DFMEA/PFMEA) and implement contingency plans to keep projects on track. Provide regular updates and data-driven reports on progress and utilize proper escalation to ensure project commitments on schedule, cost, and quality are met.
• Regulatory Compliance & Process Validation: Ensure all new packaging designs and processes meet medical device packaging standards and regulations (e.g., ISO 11607, FDA QSR, ISO 13485). Lead development of design verification and validation plans for packaging (including sterilization, shelf-life/aging, seal integrity, distribution simulation) and oversee execution of IQ/OQ/PQ process validations to demonstrate compliance and robust performance. Maintain meticulous technical documentation (specifications, protocols, reports) aligned with design control and quality system requirements throughout development.
• Customer Collaboration & Technical Leadership: Act as a customer-facing technical leader for healthcare packaging projects. Partner closely with medical device clients and internal teams (marketing, product management, quality, operations) to align development with customer needs and ensure successful product integration. Deliver clear and compelling technical presentations, progress updates, and design reviews to customers and stakeholders. Champion a customer-centric approach within R&D, ensuring excellent communication, service, and responsiveness to build confidence in DuPont’s packaging solutions.
• Continuous Improvement: Foster a culture of continuous improvement in packaging technology. Explore new materials, sustainable solutions, and advanced processing techniques (e.g., recyclable films, high-barrier coatings) to differentiate DuPont’s offerings. Apply statistical methods and data-driven problem-solving (Design of Experiments, DOE; process capability analysis; Minitab or similar tools) to characterize processes and optimize product performance. Document learnings, contribute to intellectual property (patents), and leverage insights to refine best practices and improve time-to-market for new products.

• Education & Experience: Bachelor’s degree in Materials Science, Polymer Science, Chemical Engineering, or related field with 10+ years of industry experience (or 5+ years experience with advanced degree (Masters or Ph.D.) in new product development, R&D, or process engineering roles. Demonstrated experience in polymer film extrusion and flexible packaging conversion processes is highly desired, especially for medical or pharmaceutical packaging applications.
• Medical Packaging & Regulatory Knowledge: Strong knowledge of medical device packaging requirements and standards (e.g., ISO 11607, ISO 13485, FDA regulations). Familiarity with sterilization processes (EtO, radiation, etc.) biocompatibility considerations. Experience with risk management and design control in regulated product development (FMEA, verification/validation, traceability) is a plus.
• Technical & Process Expertise: Hands‑on skills in polymer processing and packaging engineering, including film extrusion, coating/lamination, thermoforming, sealing, and related testing methods. Proficiency in process development and validation (e.g., executing IQ/OQ/PQ), and in applying statistical analysis tools (DOE, Minitab or similar) for process optimization and problem solving. Ability to interpret engineering drawings and specifications for precise, high-quality components.
• Project Leadership & Collaboration: Proven ability to lead complex projects and coordinate cross‑functional teams with minimum guidance. Strong project management skills capable of organizing and driving multiple projects to completion, balancing technical depth with timeline and budget constraints. Excellent communication and interpersonal skills, with a track record of effective collaboration across R&D, manufacturing, quality, regulatory, and commercial teams.
• Innovation & Problem‑Solving: Creative thinker with a passion for innovation in materials and processes. Demonstrated success in solving challenging technical problems through analytical thinking and experimentation. Evidence of innovation outputs (such as patents, published research, or commercialized products) is valued.
• Drive & Adaptability: Self‑motivated and results‑oriented, able to thrive in a dynamic environment. Adaptable and resilient, with the ability to manage multiple priorities and adjust to evolving project needs. Committed to continuous learning, high‑quality work, and professional growth.
• Travel Requirements: Willingness to travel up to 20% to support customer collaborations, off‑site trials, or manufacturing activities as needed.