Align

Align Technology’s 3D Printing Process team is seeking a Sr. 3D Process Engineer to join our San Jose, CA location. This in-person role involves hands-on, in-lab research and development focused on advancing additive manufacturing process control. The successful candidate will lead targeted R&D initiatives to solve fundamental process problems, serve as a subject matter expert in additive manufacturing, and collaborate with cross-functional teams to support regulatory submissions, process validation, and technology transfer activities.

Role expectations

• Independently operate new additive manufacturing equipment and post processing equipment.
• Perform material and product testing using standard and non-standard material testing equipment.
• Collect, maintain and organize data in accordance to internal standards and quality requirements.
• Participate, and lead select weekly and bi-weekly technical meetings with cross functional groups
• Present data, findings, and ideas to the process and cross-functional teams on a weekly basis
• Use statistical tools to analyze, interpret, and present experiment results.
• Be responsible for writing, maintaining, and transferring work instructions to manufacturing teams.
• Be responsible for writing, maintaining and supporting protocols for process and equipment qualifications and process transfer.
• Be responsible for writing work instructions for core Process R&D activities.
• Work closely with cross functional collaborators to support and to receive support on major project milestones.
• Serve as SME for design for additive manufacturing (DFAM) to support printing and post process development.
• Operate, collect and analyze data from polymer characterization equipment to support fundamental research in the area process-structure-property explorations.
• Apply your expertise in process-structure-property relationship exploration to study, and tune process to match desired performance and accuracy metrics.
• Use and develop methods to collect, process and analyze data from advanced metrology techniques like CT, CMM and similar equipment
• Be responsible for collection, processing and analysis of orthodontic performance data for exploring the relationship between process and performance.
• Collaborate with the manager to identify, plan, and assemble core team to support independent R&D topics. Independently design, setup and execute experiments to study process-structure-property relationships for polymer AM systems for the purpose of understanding/optimizing the manufacturing process.
• Lead and delegate tasks to Jr. team members and technicians supporting the R&D activities.
• Create, evaluate, support prototyping of equipment, jigs, fixture and tools necessary for manufacturing process internally or with external support.
• Maintain vendor relationships and be responsible for design review and release of custom equipment.
• Study and develop metrics to explore the process capability of end-to-end pilot manufacturing process for R&D products.
• Serve as lead for development of acceptance metrics, process performance criterion, and in-process monitoring criterion.
• Lead activities related to test method development and validation.
• Lead and support the planning, execution and documentation of experiment results and analysis for regulatory submissions.
• Serve as SME for internal and external audits related to process development and optimization.
• Provide the requirements for manufacturing software such as support generation, slicing, layout etc.
• Serve as a technical liaison for manufacturing software development, prototyping (coding, code editing), and testing plan.
• Support and participate in calibration, spirit committee, and safety programs.
• Foster collaboration with cross functional teams, support onboarding of Jr. engineers.
• Work in a fast-paced environment and meet critical deadlines
• Problem solve issues with attention to detail
• Actively coach, motivate, mentor and provide leadership to peers and Jr. engineers

What we're looking for

• MS degree in mechanical or Biomedical Engineering (other scientific disciplines considered) with 6-8 years of direct 3D printing experience related to SLA/ Resin based 3D printing machines, or printed medical devices.
• PhD degree in mechanical or relevant interdisciplinary degree with 3-5 years of direct focus on process or post process development for photopolymer based additive manufacturing systems. Experience with AM systems for medical device applications is a bonus.
• Demonstrable expertise in statistical analysis and design of experiments
• Demonstrable expertise in leading independent research and troubleshooting problems with logical approach.
• Experience with handling and working with chemicals such as Iso propyl alcohol, photopolymers, cleaning agents.
• Experience being comfortable with taking risk-based decisions for ambiguous problem statements.
• Excellent technical communication skills (technical writing and presentation skills)
• Strong mathematical ability to support physical process modelling using experiment observations and results.
• Experience using instruments such as CT scanners, Surface profilers, Digital microscopes and similar imaging techniques.
• Demonstrable experience in collaboration with multidisciplinary teams

Nice to Have:

• Practical coding experience in python or equivalent languages.
• Experience with end-to-end development of printing or post process parameters for a specific application or material.
• Experience working in a collaborative environment with polymer design/engineering groups.
• Experience in development of metrics for process control and process capability.
• Experience using AM tools such as solidworks, slicer and other toolpath generation SW.
• Experience with building/operating custom 3D printers, material testing, or post processing equipment.
• Experience with 3D printed devices for medical or biomechanical applications

Pay Transparency

If provided, base salary or wage rate ranges are the range in which Align reasonably expects to set a candidate’s pay for the posted position. Actual placement depends on the individual skills and experience level of a candidate plus the total compensation and equity across team members. For other locations outside of the primary location, the base salary range will be adjusted geographically.

For Field Sales roles, the salary listed is the base pay only and does not include the applicable incentive compensation plan. A cost of living adjustment may be added to base pay for higher cost areas in the U.S.

Our internship hourly rates are a standard pay determined based on the position and your location, year in school, degree, and experience.

About Align Technology

Your growth and well-being:

At Align, every smile matters. We’re committed to helping you thrive by supporting the health, growth, and well-being of our team members through a variety of tools and programs. While specific offerings may vary by location and role, Align employees can typically expect:

• Health and well-being programs to keep you thriving in both body and mind.
• Employee-exclusive discounts on Invisalign products.
• Learning opportunities through online learning resources and support for your individual development plans.
• Inclusive, global workplace that fosters collaboration, recognition and belonging.

Country and/or role specific details will be shared with you by your recruiter during the interview process.

Discover Align:

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.

Align’s core values of agility, customer, and accountability are more than words to work by, they are words we live by. The actions we take every day speak to who we are as a company and our focus on being truly impactful. We celebrate our differences, and the many ways we support one another— ultimately creating a more inclusive organization and world as we continue transforming smiles and changing lives.

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.

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.

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 our global differences 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.

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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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