Senior 3D Process Engineer

Company: Align Technology, Inc.
Location: Campbell
Posted on: January 7, 2026

Job Description:

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 were 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

Keywords: Align Technology, Inc., Redwood City , Senior 3D Process Engineer, Engineering , Campbell, California