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Process Development Engineer Jobs in Massachusetts

Access Vascular

MA

$110K - $145K/yr

The Sr. Process Development Engineer will provide technical leadership in the innovation, design, development and optimization of new and modified manufacturing processes, tooling and equipment for ...

Moderna, Inc.

Engineer II, Process Development

Norwood, MA · On-site

$74K - $118K/yr

Background in process development (late-phase preferred) and/or process characterization * Working knowledge of bioprocess engineering principles, process modeling, and Design of Experiment (DoE ...

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Process Development Engineer information

See Massachusetts salary details

$49.7K

$111K

$166.6K

How much do process development engineer jobs pay per year?

As of Jul 16, 2026, the average yearly pay for process development engineer in Massachusetts is $110,973.00, according to ZipRecruiter salary data. Most workers in this role earn between $87,900.00 and $130,000.00 per year, depending on experience, location, and employer.

What engineers make $300,000 a year?

Senior engineers in specialized fields such as petroleum, aerospace, or software engineering can earn $300,000 or more annually, especially with extensive experience, advanced skills, and leadership roles. High compensation often involves working in high-demand industries, holding managerial or executive positions, or possessing rare expertise and certifications.

What are the key skills and qualifications needed to thrive as a Process Development Engineer, and why are they important?

To thrive as a Process Development Engineer, you need a solid foundation in engineering principles, process optimization, and problem-solving, typically supported by a degree in chemical, mechanical, or industrial engineering. Familiarity with process simulation software (such as Aspen Plus or MATLAB), Six Sigma methodologies, and relevant industry certifications is often required. Strong analytical thinking, effective communication, and teamwork skills help you excel in cross-functional projects and drive continuous improvement. These skills and qualities are crucial for designing efficient processes, ensuring product quality, and supporting organizational competitiveness.

What Is a Process Development Engineer?

A process development engineer designs and plans production systems to be cost-effective, safe, and meet quality requirements for their industry. These professionals often work as part of a quality assurance team or a production management department for industrial companies, such as manufacturing or mining businesses. As a process development engineer, your job duties include reviewing the company's current production processes and designing modifications to the current system or creating new systems to increase productivity. Once you have installed or implemented the system, you make sure to test and troubleshoot it to ensure they run properly.

What are some common challenges faced by Process Development Engineers when scaling up from laboratory to production environments?

One of the main challenges Process Development Engineers encounter is ensuring that processes which work efficiently at a laboratory scale can be reliably and safely replicated in full-scale manufacturing. Differences in equipment size, process dynamics, and raw material variability can lead to unforeseen issues such as inconsistent product quality or unexpected safety hazards. Effective communication and collaboration with both R&D and production teams are essential to troubleshoot problems and optimize process parameters. Engineers often need to adapt quickly, apply problem-solving skills, and implement robust validation protocols to ensure successful scale-up.

What does a process development engineer do?

A process development engineer designs, tests, and optimizes manufacturing processes to improve efficiency, quality, and cost-effectiveness. They analyze production methods, develop new procedures, and often use tools like statistical analysis and process simulation to ensure scalable and reliable operations.

What is the difference between Process Development Engineer vs Manufacturing Engineer?

AspectProcess Development EngineerManufacturing Engineer
Primary FocusDesigning and optimizing manufacturing processes for new productsOverseeing and improving existing manufacturing processes
Work EnvironmentR&D labs, pilot plants, early-stage productionProduction floors, plant operations
Required CredentialsBachelor's or higher in engineering, experience in process designBachelor's or higher in engineering, experience in manufacturing
Industry UsagePharmaceuticals, electronics, chemicals, biotechAutomotive, consumer goods, electronics, industrial manufacturing

While both roles involve process optimization, Process Development Engineers focus on creating and refining new manufacturing processes, often in early development stages. Manufacturing Engineers typically work on maintaining and improving existing production processes to ensure efficiency and quality in ongoing operations.

What engineer makes $500,000 a year?

While most process development engineers earn between $80,000 and $150,000 annually, some senior or specialized engineers in high-demand industries or with extensive experience can earn over $200,000. Earning $500,000 typically requires executive-level roles, such as director or VP of engineering, or highly specialized positions with significant responsibilities and bonuses.

What engineers make $200,000 a year?

Senior engineers in fields such as software engineering, petroleum engineering, and aerospace engineering often earn $200,000 or more annually, especially with extensive experience, advanced skills, and in high-demand industries. Certain specialized roles, managerial positions, or engineers with advanced certifications and leadership responsibilities can also reach or exceed this salary level.
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Process Development Engineer jobs near you
Infographic showing various Process Development Engineer job openings in Massachusetts as of July 2026, with employment types broken down into 92% Full Time, 2% Part Time, and 6% Contract. Highlights an 94% In-person, 2% Hybrid, and 4% Remote job distribution, with an average salary of $110,973 per year, or $53.4 per hour.
Process Development Engineer

Process Development Engineer

Boston Materials

Billerica, MA

$120K - $180K/yr

Full-time

Medical, Dental, Vision, PTO

Re-posted 17 days ago

Job description

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 Process Development 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 
$120,000 - $180,000 a 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.
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