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Senior Process Development Engineer Jobs in Washington, DC

Inovalon

Senior Software Development Engineer

Bowie, MD · On-site

$118K - $155K/yr

Overview: The Senior Software Development Engineer L4 is expected to successfully work through ... Design, implement, unit test software, and test software following defined processes; * Fix ...

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All JobsSenior Process Development Engineer JobsSenior Process Development Engineer Jobs in Washington, DC

Senior Process Development Engineer information

See Washington, DC salary details

$84.9K

$137.1K

$193K

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

As of Jun 26, 2026, the average yearly pay for senior process development engineer in Washington, DC is $137,125.00, according to ZipRecruiter salary data. Most workers in this role earn between $117,700.00 and $152,300.00 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, and why are they important?

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.

Do R&D engineers make good money?

Senior Process Development Engineers typically earn competitive salaries that reflect their specialized skills in process optimization, research, and development. Compensation varies by industry, location, and experience, but they generally earn above-average wages compared to many other engineering roles. Advanced knowledge of tools like statistical analysis and process modeling can also influence earning potential.

Is 40 too late to be an engineer?

Age is not a barrier to becoming a senior process development engineer or any engineering role. Many engineers start or transition into the field later in life, and success depends on skills, experience, and continuous learning, such as gaining relevant certifications or technical expertise. Employers value diverse backgrounds and practical knowledge regardless of age.

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 engineer makes $500,000 a year?

Senior Process Development Engineers in specialized industries such as semiconductor manufacturing or pharmaceuticals can earn $500,000 or more annually, especially with extensive experience, advanced skills, and leadership roles. High compensation often includes bonuses, stock options, or profit sharing, and requires expertise in process optimization, automation tools, and industry certifications.

What engineers make $300,000 a year?

Senior Process Development Engineers in specialized industries such as semiconductor manufacturing, aerospace, or pharmaceuticals can earn $300,000 or more annually, especially with extensive experience, advanced skills, and relevant certifications. High compensation often reflects leadership roles, complex project management, or working in high-demand sectors with competitive salaries.
What are popular job titles related to Senior Process Development Engineer jobs in Washington, DC? For Senior Process Development Engineer jobs in Washington, DC, the most frequently searched job titles are:
What job categories do people searching Senior Process Development Engineer jobs in Washington, DC look for? The top searched job categories for Senior Process Development Engineer jobs in Washington, DC are:
Senior Process Development Engineer jobs near you

Maritime Systems Research and Development Engineer - Springfield, VA

Penn State University

Springfield, VA • On-site

Full-time

Medical, Dental, Vision, Retirement, PTO

Posted 18 days ago

Penn State University rating

7.9

Company rating: 7.9 out of 10

Based on 100 frontline employees who took The Breakroom Quiz

179th of 539 rated colleges and universities

Job description

APPLICATION INSTRUCTIONS:
  • CURRENT PENN STATE EMPLOYEE (faculty, staff, technical service, or student), please login to Workday to complete the internal application process. Please do not apply here, apply internally through Workday.
  • CURRENT PENN STATE STUDENT (not employed previously at the university) and seeking employment with Penn State, please login to Workday to complete the student application process. Please do not apply here, apply internally through Workday.
  • If you are NOT a current employee or student, please click "Apply" and complete the application process for external applicants.

Approval of remote and hybrid work is not guaranteed regardless of work location. For additional information on remote work at Penn State, see Notice to Out of State Applicants.
POSITION SPECIFICS
We are searching for a Research & Development Engineer to join our Systems Engineering and Rapid Prototyping (SERP) Division of the Applied Research Laboratory (ARL) at Penn State to serve as a Maritime Systems Project Manager at a customer site in Springfield, VA. This position will be embedded within a government program office, and requires prior Department of Defense (DoD) and Intelligence Community (IC) experience in technology development and program management. The selected candidate will ultimately be performing inherently governmental functions with significant program management responsibilities.
ARL is an authorized DoD SkillBridge partner and welcomes all transitioning military members to apply.
You will:
  • Plan and manage elements of an applied undersea research and development program to improve existing capabilities or develop new capabilities to satisfy Naval Intelligence requirements
  • Utilize project management, systems engineering, contract management, and acquisition best practices to transition advanced undersea systems to a diverse set of mission partners
  • Advise Senior Officials on topics related to Unmanned Undersea Vehicles (UUVs), Autonomous Undersea Vehicles (AUVs), robotics, autonomy, power and energy, advanced sensors, and other advanced ocean systems
  • Maintain liaison with internal and external organizations to include other intelligence agencies, academia, laboratories, and operational forces to discuss requirements, technologies, and provide timely information to senior decision makers
  • Lead the development of acquisition plans and strategy, method of solicitation, most suitable type of contract, projected lead time, and contracting packages

Additional responsibilities of higher level positions may include:
  • Conduct and coordinate complex research and development efforts to develop new systems and systems of systems, execute technology transition agreements with internal and external mission partners, and transition developed technologies to DoD and IC mission partners
  • Lead a multidisciplinary team of highly technical performers to solve complex engineering, development, test, and evaluation challenges to satisfy DoD and IC requirements

Required skills/experience areas include:
  • Experience serving in a research & development engineering role for a DoD/IC technology development program required; experience serving as a program manager or project lead for a DoD/IC technology development program is preferred
  • Broad experience in one or more of the following technology areas; Undersea Vehicles, Autonomous Systems, Sensors (acoustic, EO/IR, Sensors (or other novel phenomenology), Electronic Warfare, Communication systems (acoustic, fiber, RF), Materials Science, Advanced Manufacturing, Systems Engineering
  • Active Top Secret clearance with eligibility for access to sensitive compartmented information (TS/SCI)
  • The ability to complete a counter-intelligence scope polygraph (post-hire)

Your working location will be fully on-site in Springfield, VA. The position requires occasional travel to State College, PA and other locations.
Hiring contingent upon government customer approval.
MINIMUM EDUCATION, WORK EXPERIENCE & REQUIRED CERTIFICATIONS
If filled as Research and Development Engineer - Principal Professional, this position requires:Bachelor's Degree - Engineering or Science19+ years of relevant experienceRequired Certifications:NoneIf filled as Research and Development Engineer - Advanced Professional, this position requires:Bachelor's Degree - Engineering or Science5+ years of relevant experienceRequired Certifications:NoneIf filled as Research and Development Engineer - Senior Professional, this position requires:Bachelor's Degree - Engineering or Science14+ years of relevant experienceRequired Certifications:None
ARL's purpose is to research and develop innovative solutions to challenging scientific, engineering, and technology problems in support of the Navy, the Department of Defense (DoD), and the Intel Community (IC).
FOR FURTHER INFORMATION on ARL, visit our web site at www.arl.psu.edu.
BACKGROUND CHECKS/CLEARANCES
Employment with the University will require successful completion of background check(s) in accordance with University policies.
All positions at ARL require candidates to possess the ability to obtain a government security clearance; you will be notified during the interview process if this position is subject to a government background investigation. You must be a U.S. citizen to apply. Employment with the ARL will require successful completion of a pre-employment drug screen.
SALARY & BENEFITS
The salary range for this position, including all possible grades, is $109,300.00 - $219,600.00.**THE PROPOSED SALARY RANGE MAY BE IMPACTED BY GEOGRAPHIC DIFFERENTIAL**
Salary Structure - Information on Penn State's salary structure
Penn State provides a competitive benefits package for full-time employees designed to support both personal and professional well-being. In addition to comprehensive medical, dental, and vision coverage, employees enjoy robust retirement plans and substantial paid time off which includes holidays, vacation and sick time. One of the standout benefits is the generous 75% tuition discount, available to employees as well as eligible spouses and children. For more detailed information, please visit our Benefits Page.
CAMPUS SECURITY CRIME STATISTICS
Pursuant to the Jeanne Clery Disclosure of Campus Security Policy and Campus Crime Statistics Act and the Pennsylvania Act of 1988, Penn State publishes a combined Annual Security and Annual Fire Safety Report (ASR). The ASR includes crime statistics and institutional policies concerning campus security, such as those concerning alcohol and drug use, crime prevention, the reporting of crimes, sexual assault, and other matters. The ASR is available for review here.
EEO IS THE LAW
Penn State is an equal opportunity employer and is committed to providing employment opportunities to all qualified applicants without regard to race, color, religion, age, sex, sexual orientation, gender identity, national origin, disability or protected veteran status. If you are unable to use our online application process due to an impairment or disability, please contact 814-865-1473.
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