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Senior Process Development Engineer Jobs in Huntsville, AL

HDT Global

Senior Manufacturing Engineer

Tanner, AL · On-site

$85K - $117K/yr

The Sr MFG Engineer position will provide manufacturing engineering support to facilitate the ... including process development, tooling qualification, and first article inspection (FAI)

HDT Global

Senior Manufacturing Engineer

Tanner, AL

$85K - $117K/yr

The Sr MFG Engineer position will provide manufacturing engineering support to facilitate the ... including process development, tooling qualification, and first article inspection (FAI)

HDT Global

Senior Manufacturing Engineer

Tanner, AL · On-site

$85K - $117K/yr

The Sr MFG Engineer position will provide manufacturing engineering support to facilitate the ... including process development, tooling qualification, and first article inspection (FAI)

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All JobsProcess Development Engineer JobsSenior Process Development Engineer JobsSenior Process Development Engineer Jobs in Huntsville, AL

Senior Process Development Engineer information

See Huntsville, AL salary details

$71.5K

$115.5K

$162.5K

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

As of Aug 18, 2026, the average yearly pay for senior process development engineer in Huntsville, AL is $115,463.00, according to ZipRecruiter salary data. Most workers in this role earn between $99,100.00 and $128,200.00 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 Huntsville, AL?

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

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

The top searched job categories for Senior Process Development Engineer jobs in Huntsville, AL are:

What cities near Huntsville, AL are hiring for Senior Process Development Engineer jobs?

Cities near Huntsville, AL 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 Huntsville, AL as of August 2026, with employment types broken down into 1% As Needed, 83% Full Time, 14% Part Time, and 2% Contract. Highlights an 91% Physical, 3% Hybrid, and 6% Remote job distribution, with an average salary of $115,463 per year, or $55.5 per hour.

Senior Specialist, Manufacturing Engineer- Composites

L3 Harris

Huntsville, AL • On-site

$90K - $123K/yr

Full-time

Re-posted 5 days ago

L3Harris rating

8.1

Company rating: 8.1 out of 10

L3Harris

Based on 229 frontline employees who took The Breakroom Quiz

7.4

Company rating compared to similar companies: 7.4 out of 10

Manufacturers average

Based on 75,541 frontline employees who took The Breakroom Quiz

Job description

L3Harris is dedicated to recruiting and developing high-performing talent who are passionate about what they do. Our employees are unified in a shared dedication to our customers' mission and quest for professional growth. L3Harris provides an inclusive, engaging environment designed to empower employees and promote work-life success. Fundamental to our culture is an unwavering focus on values, dedication to our communities, and commitment to excellence in everything we do.
L3Harris is the Trusted Disruptor in defense tech. With customers' mission-critical needs always in mind, our employees deliver end-to-end technology solutions connecting the space, air, land, sea and cyber domains in the interest of national security.
Job Title: Sr Specialist, Manufacturing Engineer
Job Code: 40443
Job Location: Huntsville, AL-AMF South
Job Schedule : 4/10: Employees work 10 hour days, 4 days a week
Job Description:
We are seeking a Senior Specialist, Manufacturing Engineer to work at our new state-of-the-art Advanced Manufacturing Facility (AMF-South) in Huntsville, AL, which will be our inert manufacturing facility for fabrication and assembly of composite rocket motor hardware.
The Senior Specialist, Manufacturing Engineer is a senior professional with strong knowledge of job area and broad knowledge of project management. Manages complex projects or processes with general oversight. Communicates within and outside of own function to gain cooperation on operational processes, practices, and procedures. Makes moderate to substantial improvements to systems and processes. Contributes to achievement of departmental goals and operating plans with direct impact on the departmental results.
This is a dynamic team that requires motivated, self-starting individuals with hands-on experience. Manufacturing Engineers lead process management activities and create associated documentation for their assigned processes. They must be able to follow company procedures and requirements for the manufacture of advanced, man-rated, and high value aerospace hardware.
Essential Functions:
  • Manages large, complex, and high-visibility manufacturing projects with minimal oversight, often involving cross-functional teams and tight customer or program constraints.
  • Leads process development, optimization, and troubleshooting for advanced fabrication methods, composite layup, curing, machining, and assembly.
  • Drives significant improvements in manufacturing systems, workflows, and technologies; may also contribute to the creation of new tools, fixtures, methods, or production concepts.
  • Communicates effectively across engineering, operations, suppliers, customers, and leadership, influencing others to adopt new approaches and process changes.
  • Performs complex root cause analysis, develops corrective/preventive actions, and implements robust long-term solutions involving multiple functional areas.
  • Develops and executes operational plans for the manufacturing engineering function with short-term measurable impact on program and business performance.
  • Provides guidance, coaching, and technical leadership to engineers and technicians across the company, supporting skill development within the manufacturing engineering discipline.
  • Ensures compliance with industry standards, customer requirements, and internal quality systems; contributes to audit readiness and manufacturing risk reduction.
  • Travel: 5% travel may be required to support suppliers or other manufacturing sites, however, in times of high demand, more travel may be necessary.
  • Occasional off-shift work required to support manufacturing schedules.
  • Ability to obtain US Secret Security Clearence.

Qualifications:
  • Bachelor's Degree with 6 years Manufacturing Engineering experience, Graduate Degree with 4 years Manufacturing Engineering experience. In lieu of a degree, minimum of 10 years of prior Manufacturing Engineering experience.

Preferred Additional Skills:
  • Surface preparation for bonding rubber, insulation, metallic, and composite substrates.
  • Experience in composite tape wrapping, including process development and machine programming.
  • Hand layup and cure of insulation and composite materials.
  • Experience writing specifications and supporting procurement for new manufacturing equipment.
  • Experience with composite rocket motor nozzle fabrication.
  • Structural bonding of metallic and composite substrates.
  • Programming, operation, and qualification of composite cure ovens and/or autoclaves.
  • Precision assembly of aerospace hardware.
  • Strong GD&T background supporting part validation and tooling/fixture development.
  • CAD modeling experience.
  • Experience with tape wrap lathes, robotic systems, presses, ovens, winders, CNC machines, cutting tables, and/or autoclaves.
  • Strong cross-functional communication skills.
  • Strong problem-solving and root cause analysis skills.
  • Adaptable to a changing work environment.

#LI-HW1
L3Harris Technologies is proud to be an Equal Opportunity Employer. L3Harris is committed to treating all employees and applicants for employment with respect and dignity and maintaining a workplace that is free from unlawful discrimination. All applicants will be considered for employment without regard to race, color, religion, age, national origin, ancestry, ethnicity, gender (including pregnancy, childbirth, breastfeeding or other related medical conditions), gender identity, gender expression, sexual orientation, marital status, veteran status, disability, genetic information, citizenship status, characteristic or membership in any other group protected by federal, state or local laws. L3Harris maintains a drug-free workplace and performs pre-employment substance abuse testing and background checks, where permitted by law.
Please be aware many of our positions require the ability to obtain a security clearance. Security clearances may only be granted to U.S. citizens. In addition, applicants who accept a conditional offer of employment may be subject to government security investigation(s) and must meet eligibility requirements for access to classified information.
By submitting your resume for this position, you understand and agree that L3Harris Technologies may share your resume, as well as any other related personal information or documentation you provide, with its subsidiaries and affiliated companies for the purpose of considering you for other available positions.
L3Harris Technologies is an E-Verify Employer. Please click here for the E-Verify Poster in English or Spanish . For information regarding your Right To Work, please click here for English or Spanish .

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