Sr Research Engineer - Polymer Materials

James Hardie is the industry leader in exterior home and outdoor living solutions, with a portfolio that includes fiber cement, fiber gypsum, composite and PVC decking and railing products. Our family of trusted brands includes Hardie®, TimberTech®, AZEK® Exteriors, Versatex®, fermacell®, and StruXure®. With over 8,000 employees and U.S. headquarters in Chicago, we operate 31 sites, 6 recycling facilities, and 6 research and development centers globally. We’re united by our purpose of Building a Better Future for All™ through sustainable innovation, a Zero Harm culture, and a commitment to empowering our people and communities.

This position can be based at our Wilmington, OH or Fontana, CA plant.

About the Role

The Senior Research Engineer / Scientist – Polymer Materials will support the development, optimization, and deployment of PVC material technologies for high-performance, durable building products. This role requires deep fundamentals in polymer science and polymer engineering, with emphasis on PVC chemistry, physics, processing, and structure–property–process relationships, bridging laboratory research and manufacturing implementation.

Responsibilities

• Polymer Formulation & Materials Development
  • Develop, optimize, and evaluate PVC formulations, including base resins, stabilizer systems, lubricants, impact modifiers, process aids, fillers, and pigments.
  • Apply fundamental polymer science and engineering principles (polymer thermodynamics, viscoelasticity, molecular weight effects, phase behavior, and degradation mechanisms) to guide formulation design.
  • Demonstrate strong understanding of PVC-specific behavior, including fusion/gelation, thermal stability, shear sensitivity, rheology, and morphology development.
  • Establish and interpret structure–property–processing relationships to balance durability, mechanical performance, surface quality, and manufacturability.
  • Conduct laboratory-scale compounding, extrusion, and molding to support new product, cost, and sustainability initiatives.
  • Drive AI-assisted material characterizations and formulation development.
• Process & Manufacturing Support
  • Support PVC extrusion and compounding processes, including formulation-driven troubleshooting of surface defects, instability, degradation, dimensional control, and throughput limitations.
  • Apply polymer processing fundamentals (heat transfer, shear and elongational flow, residence time, die swell, cooling, and orientation effects) to diagnose and resolve manufacturing issues.
  • Partner with manufacturing, quality, and process engineering teams to scale laboratory formulations to robust, high-yield production.
  • Support pilot-scale and plant trials.
• Testing & Characterization
  • Design and execute experimental plans using thermal, mechanical, rheological, and environmental characterization techniques (DSC, TGA, DMA, rheometry, weathering, impact, tensile, flexural).
  • Interpret data using first-principles understanding of polymer behavior and PVC material response.
  • Maintain high standards for documentation and technical rigor.
• Project Management & Technical Communication
  • Plan and execute technical projects with defined scope and milestones.
  • Communicate complex polymer concepts clearly through written reports and presentations.
  • Collaborate with suppliers and internal stakeholders.

Requirements

• PhD in Polymer Science, Polymer Engineering, Materials Science, or Chemical Engineering with 0–7 years of experience, or MS with 3–10 years of experience.
• Strong fundamental knowledge of polymer chemistry and polymer engineering.
• Deep understanding of PVC materials including stabilization chemistry, fusion behavior, degradation mechanisms, and extrusion processing.
• Experience in AI-assisted material characterizations and formulation development for composite materials.
• Strong written and verbal communication skills.
• Travel – 35% (mainly domestic).

Preferred Qualifications

• Hands-on experience with PVC compounding, extrusion, or formulation development.
• Experience supporting high-volume manufacturing or pilot-scale operations.
• Familiarity with building materials and durability requirements.

Pay

As of the date of this posting, a good faith estimate of the current pay scale for this position is $120,000 - $135,000. Placement in the range depends on several factors such as experience, skills, geography, and internal equity and may change over time. This position qualifies for benefits and you will be eligible to participate in a bonus plan.

Benefits

• Compensation: competitive salary and bonus eligibility
• Insurance: day-one health coverage including medical, dental, vision, and life insurance
• Paid Time Off: vacation and company holidays
• Retirement: 401(k) with 6% match
• Investments: Employee Stock Purchase plan (ESP)
• Work-Life Balance: parental leave, wellness programs
• Purpose. Impact. Community: Sustainability initiatives