Senior Materials Process Engineer - ELYSIS

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About the Role

The Senior Materials Process Engineer will use their expertise in ceramic materials and processes to lead research and development efforts for advancing the technical readiness of a ceramic process used to produce proprietary and novel electrodes for the ELYSIS smelting process. This role also serves as the technical liaison, providing data-based decisions, guidance, and support to ELYSIS electrode production and industrialization teams. The position reports to ELYSIS R&D management.

A new era for the aluminum industry, ELYSIS is a revolutionary technology that eliminates all greenhouse gases and produces oxygen as a by-product. This breakthrough has the potential to drastically reduce the environmental footprint of the global aluminum industry by ending the use of carbon anodes in the smelting process. ELYSIS is a partnership between Alcoa and Rio Tinto, supported by the Canadian and Quebec governments, and Apple, with research and development locations in Canada, the United States, and France.

ELYSIS metal is currently used by companies such as Apple (MacBook Pro and iPhone 12 SE), Ab InBEV (cans), Audi (e-tron GT wheels), and Corona (cans).

About the Location

The ELYSIS US Research & Development facility is located at the Alcoa Technical Center (ATC) in New Kensington, PA, the birthplace of the aluminum industry. Near Pittsburgh, the ATC is where the ELYSIS process was first developed by a dedicated team continuing to reinvent the aluminum industry for a sustainable future.

Responsibilities

• Develop and implement process improvement programs focused on reducing scale-up, operational, and manufacturing risks associated with critical equipment and production processes.
• Lead process engineering projects by defining objectives, developing execution plans, and applying engineering analysis to improve process capability, stability, efficiency, and throughput across pilot and commercial operations.
• Provide data-driven recommendations for process optimization, equipment performance, production readiness, and operational reliability to support successful deployment and sustained operation of ELYSIS technology.
• Support the development and refinement of process specifications, operating procedures, equipment requirements, and control strategies through continuous improvement initiatives and analysis of process performance data.
• Apply sound engineering principles and a hands-on approach to troubleshoot process challenges, optimize production performance, and support manufacturing operations in laboratory, pilot, and commercial environments.
• Utilize root cause analysis, statistical methods, and problem-solving tools to identify, investigate, and implement sustainable corrective actions for process, equipment, quality, and production-related issues.
• Identify and lead initiatives that improve process efficiency, yield, reliability, product quality, capacity utilization, cost performance, and operational consistency.
• Collaborate with operations, maintenance, quality, R&D, suppliers, and external partners to ensure successful execution of process improvement projects while managing scope, schedules, budgets, and deliverables.
• Establish and monitor key process performance indicators (KPIs), analyze production data and trends, and develop actionable recommendations to improve process control and operational performance.
• Document, communicate, and standardize process improvements through technical reports, operating procedures, work instructions, presentations, and knowledge-sharing activities to ensure long-term process sustainability and organizational learning.

Requirements

• Degree in Materials Science & Engineering, Ceramics Engineering, or Chemical Engineering.
• 1-5 years of relevant work experience related to the development of ceramic materials or processes preferred.
• Demonstrated knowledge in ceramic processing, processing equipment, and process scale-up experience.
• Proven project execution and management skills.
• Strong aptitude in physical, chemical, and thermal material property characterization methods and analysis.
• Experience working in collaborative, results-driven, fast-paced team environments.
• Strong communication, organizational, and analytical skills for data management, analysis, and results presentation.

Mobility

ELYSIS is a global company with operations in Canada, France, and the United States. Business-related travel and extended-duration assignments or missions may be essential for the success of this role.

Diversity

At ELYSIS, we are committed to an inclusive environment where all voices are heard, and all cultures are respected. We value diversity and treat each other respectfully, fairly, compassionately, and with dignity regardless of differences. We particularly welcome and encourage applications from women, the LGBTQIA2 community, mature workers, people with disabilities, and people from different cultural backgrounds. ELYSIS is proud to be an equal opportunity workplace.