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Film Extrusion Product Development Engineer Jobs

Tekni-Plex

Development Engineer I

Winston Salem, NC · On-site

Product Development • Lead the development of new flexible packaging structures from concept ... Polymer films, Paper, Aluminum foil, Extrusion resins, Adhesives, Coatings, Sealant technologies ...

Tekni-Plex

Development Engineer I

Winston Salem, NC · On-site

Product Development · Lead the development of new flexible packaging structures from concept ... Polymer films, Paper, Aluminum foil, Extrusion resins, Adhesives, Coatings, Sealant technologies ...

Sealed Air Corporation

Process Engineer

Simpsonville, SC · On-site

$81K - $145K/yr

As a Process Engineer, you will serve as the technical owner of polymer film extrusion processes ... Partner with Manufacturing, Quality, Maintenance, and Product Development teams to support product ...

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Film Extrusion Product Development Engineer information

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$87.9K

$132.5K

How much do film extrusion product development engineer jobs pay per year?

As of Sep 13, 2026, the average yearly pay for film extrusion product development engineer in the United States is $87,884.00, according to ZipRecruiter salary data. Most workers in this role earn between $72,000.00 and $100,000.00 per year, depending on experience, location, and employer.

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Infographic showing various Film Extrusion Product Development Engineer job openings in the United States as of June 2026, with employment types broken down into 99% Full Time, and 1% Contract. Highlights an 93% Physical, 1% Hybrid, and 6% Remote job distribution, with an average salary of $87,884 per year, or $42.3 per hour.

Principal Process Development Engineer - Extrusion

Sandy, UT • On-site

Spectrum Plastics Group
Medical Equipment and Supplies Manufacturing • 1 - 5K employees
Learn more about Spectrum Plastics Groupexternal

Full-time

Re-posted 6 days ago

Job description

Position Summary

We are seeking an industry-leading extrusion expert to serve as a Principal Process Development Engineer (PPDE) and Subject Matter Expert (SME) for extrusion technologies across our manufacturing sites. This role will be responsible for establishing and institutionalizing best-in-class process development standards, guidelines, and technical frameworks for a wide range of extrusion processes used in medical device manufacturing.

The ideal candidate will bring deep technical expertise, a track record of innovation, and the ability to elevate organizational capability through knowledge-based process development, standardization, and cross-site collaboration.

Key Responsibilities

Technical Leadership & SME Role

  • Serve as the enterprise-wide technical authority on extrusion processes (e.g., single-lumen, multi-lumen, co-extrusion, and micro-extrusion).
  • Provide expert guidance in solving complex process challenges, including material behavior, tooling design, and process optimization.
  • Lead root cause investigations and corrective actions for critical extrusion-related issues.

Process Development Standards & Frameworks

  • Develop and deploy standardized process development methodologies aligned with scientific/knowledge-based engineering principles.
  • Establish process characterization protocols, DOE, and validation approaches (IQ/OQ/PQ).
  • Create design guidelines for tooling, die design, and downstream equipment integration.
  • Define critical process parameters (CPPs) and control strategies.

Technology Development & Innovation

  • Identify and drive adoption of advanced extrusion technologies, including micro-extrusion and multi-material extrusion.
  • Lead feasibility studies for new materials (e.g., implantable polymers such as PEEK, TPU, PCU).
  • Evaluate and recommend new equipment, automation, and digital process monitoring solutions.

Cross-Functional & Cross-Site Collaboration

  • Partner with Product Development, Operations, Quality, and Application Development teams.
  • Ensure smooth technology transfer from development to production across sites.
  • Standardize best practices across extrusion plants to ensure consistency and scalability.

Capability Building & Mentorship

  • Mentor Process Development Engineers and Technicians in extrusion science and engineering.
  • Develop and deliver training programs and technical documentation.
  • Build organizational competency in extrusion process development and validation.

Quality & Compliance

  • Ensure all processes meet regulatory requirements (FDA, ISO 13485) and internal quality standards.
  • Support validation strategies for Class II and Class III medical device components.
  • Integrate SPC, digital quality systems, and Industry 4.0 tools (IIoT) into extrusion processes.

Education

  • Bachelor’s degree in Plastics Engineering or Polymer Engineering or Mechanical Engineering (M.S, Ph.D. preferred)

Experience

  • 15+ years of hands-on experience in extrusion process development, preferably in medical device manufacturing.
  • Demonstrated expertise in:
    • Micro-extrusion and tight-tolerance tubing
    • Multi-lumen and co-extrusion processes
    • Processing of advanced polymers (e.g., PEEK, TPU)
  • Proven track record of developing and implementing process standards and scalable solutions across multiple sites.

Technical Skills

  • Strong understanding of:
    • Polymer rheology and material science
    • Tooling/die design and flow dynamics
    • Scientific extrusion principles and DOE methodologies
  • Experience with process monitoring, automation, and data analytics tools.

Preferred Qualifications

  • Experience in medical-grade thermoplastic materials.
  • Experience integrating digital manufacturing / IIoT systems into extrusion processes.
  • Experience with additional polymer processing techniques preferred.

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