Manufacturing R&D Engineer

About the role

We are seeking a results-driven Manufacturing / R&D Engineer to lead process development and continuous improvement initiatives at our Wallingford and Durham, CT facilities. This role requires expertise in Pulsed Electro-Chemical Machining (PECM) and Electro-Chemical Finishing (ECF), while supporting improvements across related manufacturing processes.

Responsibilities

• Lead process development and continuous improvement projects involving Pulsed Electro-Chemical Machining (PECM), Electro-Chemical Finishing (ECF), and related manufacturing technologies.
• Develop, validate, and implement robust, cost-effective manufacturing processes that meet customer and business requirements.
• Manage engineering projects, including defining objectives, tracking progress, communicating status, and driving timely completion of action items.
• Investigate and resolve manufacturing challenges using scientific and data-driven problem-solving methodologies.
• Design and develop tooling, fixtures, work instructions, process documentation, and validation protocols.
• Support new product introductions and process transfers from development through production.
• Collaborate with Operations, Quality, R&D, Project Engineering, and Business Development teams to improve manufacturing performance and deploy new technologies.
• Research, evaluate, and implement emerging technologies aligned with company growth strategies.
• Lead root cause investigations, corrective and preventive actions (CAPAs), and continuous improvement initiatives.
• Plan and facilitate technical reviews and project meetings throughout the project lifecycle.
• Communicate with customers regarding technical matters, project updates, and manufacturing solutions as required.
• Ensure compliance with quality system requirements, regulatory standards, and company procedures.
• Support Lean Manufacturing and continuous improvement efforts, including participation in the company idea system.
• Maintain a safe, organized work environment and comply with 6S, PPE, and safety requirements.
• Perform other duties as assigned.

Requirements

• Minimum of 10 years of manufacturing, process development, or R&D engineering experience.
• Experience in medical device manufacturing or other highly regulated industries preferred.
• Direct experience with PECM, ECF, or advanced precision manufacturing processes strongly preferred.
• Experience with GD&T, methods engineering, and fixture/tooling design.
• Knowledge of measurement systems, gauging techniques, and calibration practices.
• Understanding process validation, documentation control, and quality systems.
• Strong project management and technical problem-solving capabilities.
• Experience in applying scientific methods, root cause analysis, and continuous improvement tools.
• Strong leadership, decision-making, and organizational skills.
• Excellent written and verbal communication skills.
• Self-motivated with strong initiative and follow-through.
• Detail-oriented with methodical work habits.
• Able to collaborate effectively across all organizational levels.
• Demonstrated reliability, professionalism, and customer focus.
• Bachelor’s degree in engineering or a related technical discipline.