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Process Development Engineer Jobs in Irvine, CA (NOW HIRING)

The Process Engineer II within Manufacturing Science & Technology (MS&T) Department provides the ... Responsible for the robustness and capability of the manufacturing processes developed using ...

Product Development Engineer

Irvine, CA · On-site

$100K - $105K/yr

Job Overview: As a Product Development Engineer for the CamelBak Hardgoods category, you'll use your exceptional skills and knowledge of products and processes to bring innovative designs to ...

Senior Process Engineer

Irvine, CA

$111.60K - $144.40K/yr

Interface with Quality and R&D organizations in design control projects to integrate new products or processes into the existing manufacturing area. * Perform process development, validation, and ...

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Process Development Engineer information

See Irvine, CA salary details

$48.8K

$109.1K

$163.7K

How much do process development engineer jobs pay per year?

As of May 28, 2026, the average yearly pay for process development engineer in Irvine, CA is $109,069.00, according to ZipRecruiter salary data. Most workers in this role earn between $86,400.00 and $127,700.00 per year, depending on experience, location, and employer.

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 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 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 is responsible for designing, developing, and optimizing manufacturing processes to improve efficiency, quality, and cost-effectiveness. They often work in industries such as pharmaceuticals, chemicals, or electronics, collaborating with cross-functional teams to scale up processes from the lab to full production. Their role includes troubleshooting process issues, implementing new technologies, and ensuring compliance with safety and regulatory standards. By constantly refining processes, they help companies maintain competitive advantages and meet production goals.

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 are popular job titles related to Process Development Engineer jobs in Irvine, CA? For Process Development Engineer jobs in Irvine, CA, the most frequently searched job titles are:
What job categories do people searching Process Development Engineer jobs in Irvine, CA look for? The top searched job categories for Process Development Engineer jobs in Irvine, CA are:
What cities near Irvine, CA are hiring for Process Development Engineer jobs? Cities near Irvine, CA with the most Process Development Engineer job openings:
Process Development Engineer, Senior Staff

Process Development Engineer, Senior Staff

Confluent Medical Technologies

Laguna Niguel, CA • On-site

$110.30K - $183.80K/yr

Full-time

This job post has expired today. Applications are no longer accepted.


Job description

Salary Range:
$110,300.00 - $183,800.00
Job Description:
Confluent Medical Technologies is a financially healthy and rapidly growing medical device company whose employees are passionate about providing life-saving solutions to our customers through a collaborative and high-impact work environment. Our environment reflects a culture of growth, leadership, and innovation in which our employees can directly impact the world by doing work that truly matters.
We're looking for a Process Development Engineer, Sr. Staff to join our team in beautiful Laguna Niguel, CA. As a uniquely qualified candidate, you will:
• Work in a team environment to accomplish scientific approaches to extrusion and balloon development
• Perform process analysis, improvements and process validation (IQ/OQ/PQ)
• Develop and execute validation protocols
• Create reports and/or other communications to effectively report engineering findings
• Work with cross-functional teams to become a pivotal member of Confluent engineering
• Develop and design new process parameters, tooling, and methods for extrusion manufacturing
• Lead new product introduction, cost reduction, and revenue generating projects
• Potentially support engineering projects or cross-train in the area of polymer extrusion
• Optimize processes to meet manufacturing quality controls, build time, cost, yield targets
• Generate clear and concise work instructions, test methods, and visual standards
• Design and perform Process Characterization Study's & DOE's, support protocols and reports
• Maintain cleanliness of the work environment.
• Mentor less experienced engineers
• Perform design reviews and pre-validation assessments to ensure the safe and environmentally sound start-up of new processes
• Plan, schedule, conduct, and coordinate detailed phases of engineering work in part of a major project or in a total project of moderate scope
Education and Experience:
• Bachelor or Masters of Science in Mechanical or Bio Engineering.
• 9-12 years of experience in medical device development
• Authoritative figure in area of expertise including extrusion of medical devices
• Experience with polymer testing methodologies such including FTIR, DSC, MA
• Proficient in medical grade polymers such as Nylon 12, PBAX, Polyurethanes, PET with knowledge and experience in polymer science
• Experience with authorship of design control documents for medical devices
• Proficient in AutoCAD to create drawings for balloons, extrusion, and tooling required in balloon development
• Ability to work independently and support multi-sites
• Strong Solidworks and AutoCAD skills
• Strong Minitab experience
• Greenbelt or higher training is a plus
• Hands-on experience with a variety of catheters, balloons, and extrusion production equipment
• Strong understanding of biomaterials typical to balloons: Pebax, Nylon, Polyurethanes, and PET
• Strong overall knowledge of entire field of work, complex level engineering experience
• Familiar with technical literature and standards related to area of expertise
• Extensive hands-on experience
• Ability to work independently
• Leadership skills
• Problem solving skills
• Attention to detail, professional attitude, team player
Confluent Medical Technologies is dedicated to working collaboratively with our customers, taking their projects from rapid prototype into high volume production. Our unparalleled technical expertise, proven experience and partnership with our clients has allowed us to perfect the process necessary to deliver world-class medical devices through innovative material science, engineering, and manufacturing. Our primary capabilities include: Nitinol components and tubing, balloon expandable stents and catheters, complex catheters, biomedical textiles, and high precision polymer tubing. We take pride in our position as the leader in the medical technology space and are driven by a passion to create products that our clients have envisioned for their customers.
We regret that we are unable to sponsor employment visas or consider individuals on time-limited visa status for this position.
Confluent Medical Technologies is an equal opportunity employer.
Only qualified candidates will be contacted.