Process Development Jobs in Frederick, MD (NOW HIRING)

Job Title: Process Engineer

Job Description

This Process Engineer role supports the manufacturing of specialized thermal battery products used in highly regulated industries. You will join a small team of process engineers, each owning a specific manufacturing area, with your focus on the core battery assembly process that relies heavily on manual assembly and hands-on production support. In close collaboration with Operations, Mechanical Engineering, Battery Design Engineering, and Maintenance, you will improve manufacturing processes, troubleshoot issues, and ensure new battery designs are successfully transitioned from development into full-scale production. This position is ideal for a mechanically inclined engineer who enjoys spending significant time on the manufacturing floor solving problems and driving continuous process improvement.

Responsibilities

• Support the core battery assembly process, with a strong focus on manual assembly and production support.
• Ensure manufacturing processes are highly manufacturable, produce high-quality output, and are clearly documented for the Operations team.
• Develop, create, and maintain detailed work instructions and standard operating procedures for manufacturing processes.
• Implement continuous process improvement projects that focus on cost reduction, throughput improvement, and output increase.
• Work closely with Operations to train shop floor employees on new and existing processes, tools, and procedures.
• Collaborate with facilities and maintenance teams to identify, specify, and implement equipment upgrades and improvements.
• Troubleshoot, solve, and document manufacturing process, performance, and equipment issues in a structured and timely manner.
• Conduct root cause and corrective action (RCCA) investigations for manufacturing and process-related issues.
• Partner with Battery Design Engineering and Mechanical Engineering to transfer new battery designs from development into production.
• Monitor key performance indicators (KPIs) related to process performance, quality, and output, and use data to drive improvements.
• Support the proposed battery design process to ensure new products are manufacturable and aligned with production capabilities.
• Provide production support to resolve day-to-day manufacturing challenges and maintain stable operations.
• Collaborate with cross-functional teams in aerospace and defense-related projects to ensure manufacturing requirements are met.
• Use engineering analysis, computational modeling, and prototype build/test activities to solve technical problems and optimize processes.
• Document process changes, improvements, and lessons learned to maintain robust process knowledge and traceability.
• Perform other engineering and process-related duties as assigned to support the overall manufacturing operation.

Essential Skills

• 3–5 years of experience in an engineering or manufacturing environment.
• Hands-on, mechanically inclined approach with a strong interest in spending time on the manufacturing floor.
• Experience in process engineering within a manufacturing setting, ideally supporting assembly operations.
• Ability to solve engineering problems through analysis, computational modeling, and building/testing prototypes.
• Effective written and verbal communication skills for documenting processes and collaborating with cross-functional teams.
• Ability to collaborate with Operations, Mechanical Engineering, Battery Design Engineering, Maintenance, and other stakeholders.
• Excellent prioritization and time management skills to manage multiple projects and production support activities.
• Proficiency in Microsoft Office for data analysis, documentation, and reporting.
• Experience with PLC or similar equipment programming.
• Strong troubleshooting skills for process, performance, and equipment issues.
• Capability to conduct root cause and corrective action (RCCA) investigations.
• Comfort working in highly regulated industries such as aerospace and defense.

Additional Skills & Qualifications

• Bachelor of Science (B.S.) degree in Engineering in a field related to the supported process, typically Chemical, Mechanical, or Industrial Engineering.
• Six Sigma certification and practical application experience are a plus.
• CAD modeling experience is a plus.
• Experience supporting battery design engineers and production teams.
• Familiarity with documentation practices for work instructions and standard operating procedures.
• Experience monitoring and interpreting key performance indicators (KPIs) to drive process improvements.
• Experience in aerospace or defense manufacturing environments is beneficial.
• Interest in working on advanced battery technology and specialized power systems.

Work Environment

The work environment combines approximately 50% time on the manufacturing floor and 50% time at a desk, providing a balance between hands-on work and analytical tasks. You will collaborate closely with small, focused teams to create new processes, test their effectiveness, and refine them for production use. The core battery assembly process is highly manual rather than fully automated, offering significant opportunities for direct, practical problem-solving and process optimization. The organization offers a hands-on, entrepreneurial atmosphere with exposure to advanced thermal battery technology that supports critical defense applications such as missiles, rockets, torpedoes, and other military platforms. As part of a smaller operation backed by a global parent organization, you can make a direct impact on product development, manufacturing, and process improvements while benefiting from a location that provides a more manageable commute and cost of living than larger metropolitan areas.

This is a Permanent position based out of Westminster, MD.

The pay range for this position is $85000.00 - $95000.00/yr.

Advanced Thermal Batteries (ATB) in Westminster, MD offers a standard benefits package featuring health insurance, a 401(k) retirement plan, Paid Time Off (PTO), and alternative 9/80 work schedules.

This is a fully onsite position in Westminster,MD.

This position is anticipated to close on Jul 20, 2026.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email actalentaccommodation@actalentservices.com for other accommodation options.

San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.