Process Engineer, Quality Assurance - Billerica - Boston Materials LLC

Description

Boston Materials produces advanced materials with enhanced energy transfer properties using its patented Z-axis Carbon Fiber technology. The Company's products solve critical performance bottlenecks in applications spanning thermal, electrical, and structural use cases. Its breakthrough Liquid Metal ZRT thermal interface material is designed for the most demanding AI Infrastructure. Boston Materials is committed to expanding high-volume manufacturing in the United States. For more information, visit
ABOUT THE OPPORTUNITY
Not often in one's career do we get the chance to-
Get close to the mission. Getting a real sense of what the business does and how our work directly affects the outcome. Where everyone is involved with the company's success. No layers, no silos, no bureaucracy. Just the opportunity to make the greatest impact with the most responsibility.
Move faster. Adapting to changes in the market at record speed. No multi-layer signoffs and approvals. Instead, the latitude needed to get a new idea, product, or process off the ground quickly. Where we can experiment and test new ideas- and are encouraged to do so. We create solutions to problems that our customers truly care about, and we understand that customers won't wait for us to figure them out.
Branch beyond the role. We're not defined by past experiences or confined by our current job description. Every day offers opportunities to have influence and be challenged with new projects and tasks. Working shoulder-to-shoulder with some of the top talent in the industry, we're able to showcase our talents, expand our knowledge, develop new skills, and take ownership and act. All while contributing to the overall success of the organization.
Create critical solutions. Join us to solve the most critical challenges facing the Advanced Semiconductor, AI Infrastructure, and Advanced Materials industries.
Opportunity knocks at Boston Materials. Will you answer the call?
Your Role
This role is not a traditional Process Engineer, Quality Assurance one: you reside at the intersection of process engineering, manufacturing quality, and continuous improvement. You are active on the floor, in the data, and in the details of how materials are actually made.
You will design, validate, control, and continuously improve manufacturing processes so that quality is not inspected at the end but built in by default. You will partner closely with Engineering and Manufacturing to scale new processes, resolve yield and reliability issues, and ensure compliance with ISO 9001 and customer requirements.
You will have real authority and accountability: if something breaks, drifts, or fails a reliability test, we will rely on you to figure out why and fix it. If you like solving real problems, building systems that last, and having your fingerprints on how things are made-this role has teeth.
Your Responsibilities

• Own critical manufacturing processes from a quality and capability standpoint (process windows, control plans, PFMEAs).
• Define and maintain process parameters, acceptance criteria, and in-process controls.
• Establish SPC methodologies, control charts, and reaction plans for key variables.
• Lead root-cause analysis for process excursions, yield loss, and nonconformances.
• Develop and maintain quality documentation including control plans, work instructions, inspection plans, and validation reports.
• Support internal and external audits (ISO 9001, customer audits) with technical depth and confidence.
• Drive corrective and preventive actions (CAPA) through closure, ensuring fixes are real and sustained.
• Ensure traceability, data integrity, and disciplined change control across manufacturing processes.
• Partner with R&D and NPI teams to transition processes from development to production.
• Define process qualification plans (IQ/OQ/PQ or equivalent) for new equipment and processes.
• Identify manufacturability and reliability risks early and push for design or process changes upstream.
• Support customer qualification builds and reliability testing (e.g., accelerated life, environmental stress).
• Lead yield improvement, scrap reduction, and cycle-time reduction initiatives.
• Use data-not anecdotes-to prioritize and drive improvements.
• Help evolve manufacturing maturity as the company scales (from early production to high-volume readiness).
• Mentor junior engineers and technicians on process discipline and quality fundamentals.

Your Required Skills and Expertise

• Bachelor's degree in Engineering (Materials, Mechanical, Chemical, Manufacturing, or similar).
• 7+ years of experience in process engineering and/or quality engineering in a manufacturing environment.
• Hands-on experience with SPC, process capability analysis, and root-cause problem solving.
• Strong understanding of ISO 9001 quality systems and practical implementation.
• Experience supporting audits and interacting directly with customers on quality topics.
• Comfortable working in fast-moving, ambiguous environments where processes are still evolving.

Your Preferred Qualifications

• Advanced materials, composites, semiconductors, or precision manufacturing background.
• Experience scaling processes from pilot to production.
• Familiarity with reliability testing, accelerated life testing, or environmental stress testing.
• Experience implementing or administering SPC or manufacturing data systems.
• Lean / Six Sigma training (Green Belt or Black Belt a plus, not a requirement).

Summary of Benefits

• Health, Vision & Dental - Boston Materials pays 75% of Health, Vision and Dental Care coverage for employee and dependents
• 4 weeks of supplemental Paid Parental and Family Leave
• Unlimited Paid Time Off
• Holidays: 14 days/year

$100,000 - $120,000 a year
Boston Materials is an EOE and at the forefront of materials innovation, the key to which is diverse teams with unique backgrounds and experiences. We are committed to employing a diverse workforce with equal employment opportunities regardless of race, color, religion, sex, national origin, age, sexual orientation, gender identity, gender expression, marital status, veteran status, or disability.