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Senior Process Development Engineer Jobs in Malvern, PA

Mondo

Solutions and Development Engineer

Conshohocken, PA · On-site

$95K - $110K/yr

  • Medical

  • Dental

  • Vision

  • Retirement

  • PTO

About the Role We are seeking a Senior Software Engineer to join a collaborative technology team ... Learn and manage the platform's data ingestion and processing workflows. * Design, develop, enhance ...

AIRCO

Engineer I

Philadelphia, PA

Support senior engineers on cross-functional development projects and technical problem-solving * Support evaluation of new process technologies and development of process solutions * Analyze data ...

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All JobsProcess Development Engineer JobsSenior Process Development Engineer JobsSenior Process Development Engineer Jobs in Malvern, PA

Senior Process Development Engineer information

See Malvern, PA salary details

$73.6K

$118.8K

$167.3K

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 Malvern, PA is $118,848.00, according to ZipRecruiter salary data. Most workers in this role earn between $102,100.00 and $132,000.00 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 Malvern, PA?

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

What cities near Malvern, PA are hiring for Senior Process Development Engineer jobs?

Cities near Malvern, PA 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 Malvern, PA as of August 2026, with employment types broken down into 100% Full Time. Highlights an 70% In-person, 10% Hybrid, and 20% Remote job distribution, with an average salary of $118,848 per year, or $57.1 per hour.

Senior Medical Tubing Extrusion Engineer

Martech Medical Products

Harleysville, PA • On-site

$100K - $138K/yr

Full-time

Posted 18 days ago

Job description

Senior Medical Tubing Extrusion Engineer
Onsite Position
Relocation assistance is not available
Join Our Team
Join a growing medical device manufacturing organization where your technical expertise will directly impact the development and production of innovative healthcare technologies. As a Senior Medical Tubing Extrusion Engineer, you will serve as the technical leader for extrusion process development, validation, optimization, and commercialization activities. This role offers the opportunity to work on complex medical tubing products, influence manufacturing strategy, mentor technical talent, and drive continuous improvement in a highly regulated environment.
Position Summary
The Senior Medical Tubing Extrusion Engineer serves as the subject matter expert for medical tubing extrusion processes and technologies. This individual leads process development, validation, equipment and tooling improvements, and new product introduction activities while partnering closely with Manufacturing, Quality, Maintenance, Supply Chain, Project Management, and Commercial teams.
This role combines hands-on engineering expertise with technical leadership and offers the opportunity to influence both current operations and future manufacturing capabilities.
How You Will Contribute
  • Lead the development, optimization, validation, and sustainment of medical tubing extrusion processes to ensure product quality, efficiency, and compliance.
  • Design, develop, qualify, and maintain extrusion tooling, including dies, tips, mandrels, sizing fixtures, and downstream tooling.
  • Lead process and equipment validation activities, including IQ, OQ, PQ, process characterization, and capability studies.
  • Serve as the technical lead for extrusion-related New Product Introduction (NPI), commercialization, scale-up, and technology transfer projects.
  • Drive continuous improvement initiatives focused on yield improvement, process capability, throughput, cost reduction, and operational excellence.
  • Troubleshoot complex process, tooling, equipment, and product quality issues using structured problem-solving methodologies.
  • Conduct root cause investigations and implement effective corrective and preventive actions.
  • Develop and maintain engineering documentation, validation reports, SOPs, work instructions, and process standards.
  • Evaluate manufacturability, capacity requirements, and technical feasibility for new business opportunities and customer programs.
  • Mentor and train engineers, technicians, and manufacturing personnel to strengthen technical capabilities throughout the organization.
  • Support customer audits, supplier assessments, technical reviews, and regulatory inspections.
  • Evaluate and implement new materials, equipment, automation technologies, and manufacturing methods to expand organizational capabilities.
  • Lead cross-functional projects that support strategic manufacturing and business objectives.
Required Qualifications
  • Bachelor's degree in Mechanical Engineering, Polymer Engineering, Chemical Engineering, Manufacturing Engineering, Biomedical Engineering, or a related engineering discipline.
  • 7+ years of experience in extrusion engineering, polymer processing, medical device manufacturing, or a related manufacturing environment.
  • Demonstrated expertise in medical tubing extrusion process development, optimization, and troubleshooting.
  • Strong knowledge of thermoplastics, polymer behavior, and extrusion processing principles.
  • Experience designing and developing extrusion tooling, including dies, tips, mandrels, and sizing systems.
  • Experience leading process and equipment validations, including IQ, OQ, and PQ activities.
  • Strong understanding of Design of Experiments (DOE), Statistical Process Control (SPC), process characterization, and capability analysis.
  • Experience conducting root cause investigations and implementing corrective and preventive actions.
  • Strong technical writing, project management, and communication skills.
  • Demonstrated ability to lead technical projects and mentor engineers, technicians, and manufacturing personnel.
Preferred Qualifications
  • Experience in medical device manufacturing.
  • Knowledge of FDA Quality System Regulations (QSR), ISO 13485, Good Manufacturing Practices (GMP), Design Controls, Risk Management, and Change Control processes.
  • Experience with complex medical tubing products, including multilumen, tapered, reinforced, microbore, and specialty extrusions.
  • Experience supporting NPI, customer qualification, commercialization, and technology transfer activities.
  • Lean Six Sigma Green Belt or Black Belt certification.
  • Experience with SolidWorks or equivalent CAD software.
  • Experience supporting technical quoting and manufacturability assessments.
Work Authorization Requirement: Applicants must be legally authorized to work in the United States on an unrestricted basis. The Company does not sponsor employment visas or provide immigration-related sponsorship now or in the future. Candidates requiring current or future sponsorship for employment authorization are not eligible for consideration.

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