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Senior Process Development Engineer Jobs in Acton, MA

Ttmtech

Senior Process Engineer

Salem, NH

$103K - $134K/yr

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

The Senior Process Engineer serves as a technical leader within the organization, partnering cross ... Partner with Program teams and customers on product design and process development to support new ...

HyperLight

Senior Photonics Process Engineer

Cambridge, MA · On-site

$125K - $185K/yr

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

As a Senior Photonics Process Development Engineer , you will be a key player in driving the development, optimization, and scaling of fabrication processes on the TFLN platform, working closely with ...

TTM Technologies

Senior Process Engineer

Salem, NH · On-site

$103K - $134K/yr

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

The Senior Process Engineer serves as a technical leader within the organization, partnering cross ... Partner with Program teams and customers on product design and process development to support new ...

HyperLight

Senior Photonics Process Engineer

Cambridge, MA · On-site

$125K - $185K/yr

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

As a Senior Photonics Process Development Engineer , you will be a key player in driving the development, optimization, and scaling of fabrication processes on the TFLN platform, working closely with ...

HyperLight

Senior Photonics Process Engineer

Cambridge, MA · On-site

$125K - $185K/yr

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

As a Senior Photonics Process Development Engineer , you will be a key player in driving the development, optimization, and scaling of fabrication processes on the TFLN platform, working closely with ...

HyperLight

Senior Photonics Process Engineer

Cambridge, MA · On-site

$125K - $185K/yr

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

As a Senior Photonics Process Development Engineer , you will be a key player in driving the development, optimization, and scaling of fabrication processes on the TFLN platform, working closely with ...

Quanterix

Sr. Process Engineer

Billerica, MA · On-site +1

$105K - $130K/yr

  • Medical

  • Dental

  • Vision

  • Retirement

  • PTO

Sr. Process EngineerBillerica, MA Quanterix is a global leader in ultra-sensitive biomarker ... D on IVD and RUO product development. * Write documentation for IVD and RUO products and processes.

New

Honeywell International, Inc.

Sr Process Engineer

Woburn, MA · On-site

$111K - $143K/yr

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

As a Senior Process Engineer - Electronics Assembly here at Honeywell Aerospace, you will be ... Lead development, qualification, and continuous improvement of electronics assembly processes (SMT ...

Syner-G

Sr. Process Engineer

Bedford, MA

$109K - $141K/yr

  • PTO

Syner-G is seeking a Senior Process Engineer with 10+ years of experience supporting the design ... Review and support development of engineering deliverables including process flow diagrams (PFDs ...

Syner-G

Sr. Process Engineer

Bedford, MA · On-site

$109K - $141K/yr

  • PTO

Syner-G is seeking a Senior Process Engineer with 10+ years of experience supporting the design ... Review and support development of engineering deliverables including process flow diagrams (PFDs ...

Syner-G

Sr. Process Engineer

Bedford, MA

$109K - $141K/yr

Syner-G is seeking a Senior Process Engineer with 10+ years of experience supporting the design ... Review and support development of engineering deliverables including process flow diagrams (PFDs ...

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Showing results 21-40

All JobsProcess Development Engineer JobsSenior Process Development Engineer JobsSenior Process Development Engineer Jobs in Acton, MA

Senior Process Development Engineer information

See Acton, MA salary details

$82.6K

$133.3K

$187.7K

How much do senior process development engineer jobs pay per year?

As of Aug 16, 2026, the average yearly pay for senior process development engineer in Acton, MA is $133,348.00, according to ZipRecruiter salary data. Most workers in this role earn between $114,500.00 and $148,100.00 per year, depending on experience, location, and employer.

What does a senior process development engineer do?

A Senior Process Development Engineer is responsible for designing, developing, and optimizing manufacturing processes to improve efficiency, quality, and cost-effectiveness. They often lead teams in scaling up processes from the laboratory to full production, troubleshoot technical issues, and implement new technologies or methods. Additionally, they collaborate with cross-functional teams, including R&D, quality assurance, and production, to ensure processes meet regulatory and safety standards. Their expertise helps companies maintain competitive advantages and meet production goals.

What are the key skills and qualifications needed to thrive as a senior process development engineer?

To thrive as a Senior Process Development Engineer, you need a strong background in chemical or mechanical engineering, process optimization, and project management, typically supported by a relevant engineering degree. Familiarity with CAD software, process simulation tools (such as Aspen Plus or MATLAB), and Six Sigma or Lean Manufacturing certifications is often required. Excellent problem-solving, leadership, and communication skills help you coordinate cross-functional teams and drive continuous improvement. These skills are crucial for developing efficient, scalable processes that meet quality standards and business goals.

What are some common challenges a senior process development engineer may face when scaling up a new process from the lab to full production?

Senior Process Development Engineers often encounter challenges such as maintaining product quality and consistency when transitioning from small-scale laboratory experiments to large-scale manufacturing. This process typically involves troubleshooting equipment limitations, optimizing process parameters, and ensuring compliance with safety and regulatory standards. Effective collaboration with cross-functional teams, such as R&D, manufacturing, and quality assurance, is crucial to address these challenges and achieve a smooth scale-up. Adaptability and problem-solving skills are essential to navigate unexpected issues that may arise during this transition.

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

AspectSenior Process Development EngineerProcess Engineer
CredentialsBachelor's or Master's in Chemical, Mechanical, or Industrial Engineering; experience in process developmentBachelor's degree in Engineering or related field; entry to mid-level experience
Work EnvironmentResearch and development labs, manufacturing facilities, cross-functional teamsManufacturing plants, production lines, process optimization teams
Industry UsagePharmaceuticals, chemicals, biotech, manufacturingManufacturing, chemical processing, consumer goods

The main difference is that Senior Process Development Engineers focus on developing and optimizing new processes, often in R&D settings, while Process Engineers typically oversee existing manufacturing processes to improve efficiency and quality. Senior roles involve more strategic planning and innovation, whereas Process Engineers focus on day-to-day process operations.

What are popular job titles related to Senior Process Development Engineer jobs in Acton, MA?

For Senior Process Development Engineer jobs in Acton, MA, the most frequently searched job titles are:

What job categories do people searching Senior Process Development Engineer jobs in Acton, MA look for?

The top searched job categories for Senior Process Development Engineer jobs in Acton, MA are:

What cities near Acton, MA are hiring for Senior Process Development Engineer jobs?

Cities near Acton, MA with the most Senior Process Development Engineer job openings:

Senior Process Development Engineer jobs near you
Infographic showing various Senior Process Development Engineer job openings in Acton, MA as of August 2026, with employment types broken down into 1% As Needed, 86% Full Time, 11% Part Time, and 2% Contract. Highlights an 91% Physical, 3% Hybrid, and 6% Remote job distribution, with an average salary of $133,348 per year, or $64.1 per hour.

Sr. Manufacturing Process Development Engineer, Consumer Technology

VulcanForms

Devens, MA • On-site

$106K - $146K/yr

Full-time

Medical, Dental, Vision, Life, Retirement, PTO

Re-posted 7 days ago

Job description

About Us
Founded in 2015 to develop the world's first industrially scalable laser metal additive manufacturing solution, VulcanForms is reshaping how the world manufactures critical products. We build and operate advanced digital infrastructure that enables innovation, accelerates growth, and supports sustainability across aerospace, defense, medical, and other essential industries. Through our vertically integrated capabilities, including scalable additive manufacturing and precision machining, we deliver true end-to-end production at scale by combining cutting-edge technology with a foundation of proven industrial craftsmanship. Our team brings deep expertise in manufacturing, materials science, software, automation, and operations, united by a shared commitment to quality, curiosity, and accountability. We foster an inclusive culture where people take ownership, solve meaningful problems, and continuously learn, because we believe diverse perspectives lead to better outcomes.
Job Purpose
As a Sr. Manufacturing Process Development Engineer, Consumer you will own the end-to-end technical framework that translates customer designs into repeatable, high-performance physical products within our consumer-technology business. You will bridge the gap between material science and high-volume digital production, overseeing the comprehensive process pipeline-including laser parameter optimization, print layouts, and post-printing thermal treatments. Success in this role means establishing stable, optimized processing windows that guarantee the mechanical, aesthetic, and metallurgical integrity of parts coming off our advanced production lines.
Key Responsibilities
  • End-to-End Process Ownership: Define, document, and optimize the comprehensive 3D digital manufacturing workflow, owning process intent from initial laser print files through stress-relief, heat treatment, and final part extraction.
  • Recipe & Parameter Development: Pioneer and refine high-temperature thermal recipes, laser interaction parameters, and advanced printing strategies to meet strict mechanical properties, surface finish requirements, and microstructural tolerances.
  • Data-Driven Optimization: Design and execute complex Design of Experiments (DOE) using statistical software (such as Minitab or JMP) to analyze process capability, drive continuous yield improvements, and minimize scrap rates.
  • Defect & Root Cause Analysis: Lead technical investigations into failed builds, non-conformances, geometric distortions, and metallurgical variations, implementing robust corrective and preventive actions (CAPA).
  • DFAM Partnership: Collaborate with Applications and Design teams on Design for Additive Manufacturing (DFAM) reviews, evaluating customer CAD geometries, support structures, and post-processing constraints to ensure stable manufacturability.
Qualifications
  • Experience: 5+ years of experience in process development, metallurgical engineering, or advanced materials processing within high-precision manufacturing (such as Metal Additive Manufacturing, Semiconductor fabrication, Aerospace processing, or advanced Injection Molding).
  • Statistical Rigor: Proven ability to build and analyze statistical process control (SPC) data and DOEs to establish highly repeatable manufacturing windows.
  • Materials Literacy: Deep understanding of material behavior, thermal stress development, microstructural evolution, or mechanical testing protocols.
  • Education: Bachelor's or Master's degree in Materials Science, Metallurgical Engineering, Mechanical Engineering, Chemical Engineering, or a related technical discipline.
  • Soft Skills: Analytical, structured problem solver with excellent cross-functional communication skills to translate complex processing data into actionable engineering workflows.

VulcanForms offers a competitive salary and equity package. Actual compensation is based on factors such as the candidate's skills, qualifications, and experience. In addition, VulcanForms provides comprehensive benefits including medical, dental, vision, and life insurance; generous paid time off; and a 401(k) plan with company match.
The annual base salary range for this position is $106,000 to $146,000.

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