Process Development Engineer Jobs in Rhode Island

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-
Reporting to the Sr. Manager, Operations, the Manufacturing Process Engineer is responsible for supporting safe, reliable, and efficient manufacturing operations in a Process Safety Management (PSM) covered facility. This role partners closely with operations, maintenance, and EHS teams to optimize process performance, maintain regulatory compliance, and implement continuous improvement initiatives.
The Manufacturing Process Engineer plays a key role in process safety, operational excellence, troubleshooting, and capital project support, ensuring processes operate within defined safe operating limits while driving improvements in yield, reliability, and efficiency.
How will you do it-
Process Safety & Regulatory Compliance

• Support compliance with OSHA Process Safety Management (29 CFR 1910.119) and other applicable regulatory requirements.
• Participate in Process Hazard Analyses (PHA) including HAZOP, HAZID, and FMEA studies to identify and mitigate process hazards.
• Lead or support Management of Change (MOC) reviews for modifications to process equipment, chemicals, operating procedures, or control systems.
• Support Pre-Startup Safety Reviews (PSSR) and Operational Readiness Reviews (ORR) for new, modified, or idled processes prior to startup.
• Maintain and update Process Safety Information (PSI) including process flow diagrams, P&IDs, and operating limits.
• Lead or participate in incident investigations and root cause analyses for process safety events, equipment failures, and near misses.
• Support regulatory inspections, internal audits, and compliance reporting related to PSM elements.

Process Engineering & Operations Support

• Collaborate with operations, maintenance, and EHS teams to troubleshoot process issues and implement safe, sustainable solutions.
• Monitor and analyze process data to ensure operation within defined safe operating limits and identify opportunities for improvement.
• Develop, review, and maintain process documentation, including operating procedures, process flow diagrams, and engineering standards.
• Implement and monitor process control strategies to maintain stable and safe operating conditions.
• Provide technical support during process startups, shutdowns, and plant outages.
• Assist in training operators and technical staff on process changes, safety requirements, and updated procedures.

Operational Excellence & Continuous Improvement

• Apply operational excellence and lean manufacturing principles to improve safety, productivity, and process reliability.
• Lead continuous improvement initiatives focused on yield improvement, waste reduction, energy efficiency, and process capability.
• Utilize Lean and problem-solving tools such as root cause analysis, Kaizen, 5S, and value stream mapping to eliminate inefficiencies.
• Analyze production and process data to identify trends and implement data-driven improvements.

Capital Projects & Process Development

• Lead or support small capital projects including scope development, design review, equipment specification, and commissioning.
• Serve as the manufacturing representative on larger capital projects, supporting design reviews, P&ID development, and operability assessments.
• Participate in equipment and system design reviews to ensure operability, maintainability, and safety requirements are met.
• Support commissioning and startup activities for new equipment and process improvements.

Why you are right for the job-
Required:

• Bachelor's degree in chemical engineering, mechanical engineering, or related engineering discipline.
• 5+ years of experience in manufacturing, chemical processing, or industrial production environments.
• Experience working in or supporting a PSM-covered process facility.
• Knowledge of process safety principles, hazard analysis methodologies, and operating limits.
• Experience with process troubleshooting, data analysis, and continuous improvement initiatives.
• Demonstrated experience with lean manufacturing methodologies.
• Experience with project management and leading and delivering projects in a manufacturing environment
• Strong communication skills and ability to collaborate across operations, engineering, maintenance, and EHS teams.

Preferred:

• Familiarity with process control systems and industrial automation.
• Experience supporting capital projects or equipment commissioning.
• Certification or training in PSM, Lean Six Sigma, or reliability engineering.

What to expect-
This position operates within a manufacturing facility handling regulated process chemicals and equipment. The role may require frequent presence in production areas, participation in plant outages or startup activities, and adherence to all facility safety requirements.
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 employee 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 $105,000 and $125,000 USD/year based on experience.
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.
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.
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.