Senior Director of Engineering - Aerosol Jet 3D Printing, Motion Control & Electronics

Key Responsibilities

• Define and execute the engineering roadmap for next-generation Aerosol Jet 3D printing systems and subsystems (motion platforms, deposition heads, electronics, and control architecture).
• Lead cross-functional teams in mechatronics, electrical, firmware, and process control engineering.
• Aligning engineering priorities with business goals for performance, yield, cost, and manufacturability.
• Provide technical oversight in fluid dynamics, aerosol generation, atomization, and printhead design.
• Champion engineering best practices for reliability, system integration, and design for manufacturing (DFM/DFA).
• Direct the design and optimization of precision motion and positioning systems, including linear/rotary stages, servo drives, feedback sensors, and motion controllers.
• Oversee system-level integration between mechanical motion, electronic control, and deposition subsystems to achieve micro-level repeatability and throughput goals.
• Ensure implementation of advanced motion algorithms, trajectory planning, and synchronization with deposition timing for high-accuracy material placement.
• Guide architecture and development of control electronics, power systems, and embedded firmware for real-time control of Aerosol Jet processes.
• Ensure robust system integration between sensors, motion controllers, PLCs, and user interfaces (HMI/software).
• Oversee design validation, EMI/EMC compliance, and safety certification for global markets.
• Implement stage-gate product development, configuration control, and design verification processes.
• Drive outsourced manufacturing and supplier collaboration for motion subsystems, electronics, and precision assemblies.
• Establish strong partnerships with contract manufacturers, ensuring technical transfer and sustaining support.
• Manage engineering budgets, schedules, and resource allocation across global sites.
• Build and mentor a world-class engineering team across hardware, controls, and system integration disciplines.
• Foster a culture of innovation, accountability, and technical excellence.
• Develop engineering leaders capable of scaling with the organization’s growth.

Qualifications

• Bachelor’s degree in Mechanical, Electrical, or Mechatronics Engineering required.
• Advanced degree (MS/PhD) in relevant field (e.g., Controls, Mechatronics, Applied Physics, or Materials Science) preferred.
• 15+ years of engineering experience with 7+ years in senior leadership roles within high-precision equipment industries (3D printing, semiconductor tools, inkjet, or industrial automation).
• Understanding and expertise in Aerosol Jet, inkjet printing, or micro dispensing systems, including understanding of atomization, aerosol transport, and deposition control.
• Strong background in motion control, embedded systems, and precision mechatronics.
• Demonstrated success scaling engineering organizations and transitioning products from R&D to volume manufacturing.
• Experience managing outsourced design and manufacturing partnerships globally.

Skills

• Deep system-level understanding of 3D printing technology and motion control systems, with understanding of automation integration for scaling mass production operations in manufacturing.
• Strong analytical and problem-solving abilities with a focus on design robustness and process stability.
• Effective communicator capable of influencing across technical and executive levels.
• Skilled in risk management, root cause analysis, and process improvement.