The Application and Innovation DFM Engineer is dedicated to addressing the most critical challenges in manufacturing design and production, leveraging expertise in critical disciplines (i.e. additive manufacturing, mechanical design, FMA, etc.) to identify customer needs, validate solutions and scale manufacturing processes.

This role focuses on accelerating the development of advanced applications and innovative technology solutions by collaborating with customers and internal teams. The engineer works to deliver tailored, high-impact solutions that reduce risks, improve ROI, and speed time-to-market for critical applications. By exploring, innovating, developing and validating, this position plays a key role in advancing the company’s competitive edge in the industry.

Key Responsibilities

Explore

  • Identify customer needs and application opportunities in manufacturing challenges.
  • Collaborate with cross-functional teams to funnel needs into concrete solutions.
  • Use systematic screening approaches to design tailored strategies for customer applications.

Innovate

  • Partner with customers to design integrated solutions combining hardware, software, materials, and processes.
  • Share insights from applications to guide the development of tools and processes that unlock greater value.
  • Overcome technical challenges in product and process design to enhance functionality and performance.
  • Generate innovative application-driven solutions aligned with business objectives.

Develop

  • Lead the process from pre-prototyping to delivering proven, tailored solutions.
  • Build concept and prototype solutions to assess feasibility
  • Identify and mitigate risks to ensure robust and scalable manufacturing processes.
  • Develop and optimize designs to meet application requirements.
  • Define process workflows and establish Critical-To-Quality (CTQ) attributes.
  • Ensure solutions meet stringent industry and customer requirements.

Validate

  • Apply a risk-based approach to process, equipment, and product validation.
  • Establish qualified production processes for serial manufacturing.
  • Collaborate with quality and regulatory teams to ensure compliance with industry standards.

Scale

  • Transfer knowledge and technology gathered through the process to enable the scaling of solutions to meet business requirements.
  • Facilitate the transition from development to full-scale production at manufacturing sites.
  • Ensure robust implementation of processes and solutions for serial manufacturing.

This role is at the forefront of additive manufacturing innovation, requiring a combination of technical expertise, customer collaboration, and a results-driven approach to solve some of the most complex challenges in the industry.

Skills, Knowledge & Expertise

  • Education

o Bachelor’s degree in engineering, such as:

  • Mechanical
  • Mechatronics
  • Aerospace
  • Materials
  • Additive Manufacturing

o Advanced degrees (Master’s or Ph.D.) in related fields are desirable.

  • Technical skills

o Proficiency in CAD and simulation tools (e.g., SolidWorks, Siemens NX, ANSYS).

o Good understanding of mechanical systems to enable designing of fixtures/tools and optimization of complex hardware

o Familiarity with design for additive manufacturing (DfAM) and Critical-to-Quality (CTQ) attributes.

o Desirable strong knowledge of additive manufacturing technologies (e.g., SLS, SLA, DLP, DMP).

o Experience in process validation and risk-based approaches in manufacturing.

o Data analytics: Collect, process, and analyze large datasets. Develop and implement data collection systems and strategies, interpret data and identify trends and patterns, create reports and visual presentations to communicate findings, apply statistical methodologies to analyze data.

  • Problem-Solving and Innovation

o Proven ability to solve complex design and manufacturing challenges.

o Creativity in developing tailored solutions combining hardware, software, materials, and processes.

o Strong analytical and statistical skills.

o Experience with various problem-solving methodologies (e.g., Six Sigma, Lean)

o Develop and implement effective solutions to address identified issues.

o Collaborate with cross-functional teams to ensure comprehensive problem resolution.

o Monitor and evaluate the effectiveness of implemented solutions.

o Identify opportunities for innovation and propose strategic projects

  • Project Management and Collaboration

o Strong organizational and project management skills to drive applications from concept to production.

o Effective collaboration with cross-functional teams, customers, and stakeholders.

  • Communication

o Excellent written and verbal communication skills for technical documentation and customer interaction.

o Ability to present complex technical concepts clearly to diverse audiences.

  • Experience

o Experience in scaling manufacturing processes from prototype to full production.

o 3-5 years of experience in:

  • Additive manufacturing Engineer
  • Mechanical Design Engineer
  • Applications Engineer
  • DFM Process Engineer
  • Electrical Engineer

o Experience in developing and validating manufacturing processes or applications.

o Hands-on experience with industrial-grade 3D printing systems and materials.

o Background in regulated industries such as medical devices, aerospace or automotive.

Language:

English Upper intermediate B2 to Advance C1

About Align Technology

Your growth and well-being:

At Align, every smile matters. We are committed to supporting your health, contentment, and professional development through tools and initiatives designed to help you thrive. While benefits may vary by location, you can expect the following wherever you join us:

  • Health and well-being programs to keep you thriving in both body and mind.
  • Employee discounts on Invisalign products.
  • Learning opportunities though online learning resources and support for your individual development plans.
  • Inclusive workspace that fosters diversity and collaboration.

Country-specific details will be shared with you by your recruiter during the interview process.

Discover Align:

At Align Technology, we are a global community of game-changers and smart team players, united by our belief in the power of a smile. Our dynamic team of exceptional employees is dedicated to transforming the industry and creating extraordinary outcomes every day.

We foster a culture where thinking differently and seeking new experiences are not just encouraged but celebrated. With the Align Mindset, we empower each other, ensuring every voice is heard and valued in an inclusive environment that inspires creativity and collaboration.

As part of our commitment to innovation, Align Technology includes exocad and Cubicure, companies that enhance our offerings and extend our impact to industry transformation.

Eager to learn how we embrace diversity and nurture employee well-being?

Explore Align's culture here!

Want to discover more about exocad and Cubicure? Click on their names for additional information.

Applicant Privacy Policy:

Review our Applicant Privacy Policy for additional information.

Global Diversity Statement:

At Align, we believe in the power of a smile, and we know that every smile is as unique as our employees. As we grow, we are committed to building a workforce rich in diverse cultural backgrounds and life experiences, fostering a culture of open-mindedness and compassion. We live our company values by promoting healthy people and healthy communities, all with the intent of changing millions of lives, one unique smile at a time.

Equal Opportunity Statement:

Align Technology is an equal opportunity employer. We are committed to providing equal employment opportunities in all our practices, without regard to race, color, religion, sex, national origin, ancestry, marital status, protected veteran status, age, disability, sexual orientation, gender identity or expression, or any other legally protected category. Applicants must be legally authorized to work in the country for which they are applying, and employment eligibility will be verified as a condition of hire.

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Confirmed 18 hours ago. Posted 30+ days ago.

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