New Product Development Engineer

DuPont Spectrum Healthcare Solutions is seeking a New Product Development Engineer Medical Films & Flexibles Packaging to drive advanced packaging design (films & conversion) & process development for critical healthcare and medical device applications. This technical role offers the opportunity to lead high-impact new product and process development programs from concept through commercialization within a world-class R&D and manufacturing environment. (Location Pleasant Prairie WI)

Role Overview
Lead end-to-end development of medical films and flexible packaging solutions applying deep expertise to design scale-up novel packaging technologies that meet stringent medical device requirements. Primary job scope includes hands-on new product and process development and project leadership all the way from translating customer needs into innovative packaging designs and materials through prototyping pilot-scale process development validation (IQ/OQ/PQ) and tech transfer to full-scale commercial launch. By applying scientific rigor and project management best practices you will help expand and grow DuPont Spectrum Life Sciences medical films & packaging innovation portfolio while ensuring regulatory compliance and quality reliable performance.

Key Responsibilities

• Flexibles Packaging New Product Design & Development: Ideate and develop new medical-grade films and flexible packaging form factors tailored for healthcare applications such as medical devices. Translate customer and application requirements into clear design specifications and structureproperty-process hypotheses to optimize performance requirements such as barrier properties mechanical strength and compatibility with sterilization methods. Lead prototype development process development testing of films (multi-layer) laminates and form factors (e.g. pouches header bags conversion films) that ensure sterile barrier integrity and durability for medical device packaging.
• Flexibles Packaging & Conversion Process Development: Develop and optimize polymer film extrusion (blown film) and packaging conversion processes (e.g. film casting slitting pouch forming sealing). Scale up new products from prototyping concepts through pilot trials to manufacturing ensuring processes are robust efficient and capable of high-quality output. Collaborate with manufacturing engineers on process scale-up and technology transfer to establish process parameters standard operating and procedures Troubleshoot complex process issues using root cause analysis and implement corrective and preventive actions to continuously improve yield reliability and product quality.
• Project Management & Risk Mitigation: Lead and drive cross-functional new product development project teams through a structured stage-gate development process from concept to commercial launch. Develop and manage project plans defining scope timeline resource needs and critical milestones. Proactively identify and mitigate risks (technical regulatory or timeline) using risk management practices (e.g. DFMEA/PFMEA) and implement contingency plans to keep projects on track. Provide regular updates and data-driven reports on progress and utilize proper escalation to ensure project commitments on schedule cost and quality are met.
• Regulatory Compliance & Process Validation: Ensure all new packaging designs and processes meet medical device packaging standards and regulations (e.g. ISO 11607 FDA QSR ISO 13485). Lead development of design verification and validation plans for packaging (including sterilization shelf-life/aging seal integrity distribution simulation) and oversee execution of IQ/OQ/PQ process validations to demonstrate compliance and robust performance. Maintain meticulous technical documentation (specifications protocols reports) aligned with design control and quality system requirements throughout development.
• Customer Collaboration & Technical Leadership: Act as a customer-facing technical leader for healthcare packaging projects. Partner closely with medical device clients and internal teams (marketing product management quality operations) to align development with customer needs and ensure successful product integration. Deliver clear and compelling technical presentations progress updates and design reviews to customers and stakeholders. Champion a customer-centric approach within R&D ensuring excellent communication service and responsiveness to build confidence in DuPonts packaging solutions.
• Continuous Improvement: Foster a culture of continuous improvement in packaging technology. Explore new materials sustainable solutions and advanced processing techniques (e.g. recyclable films high-barrier coatings) to differentiate DuPonts offerings. Apply statistical methods and data-driven problem-solving (Design of Experiments DOE; process capability analysis; Minitab or similar tools) to characterize processes and optimize product performance. Document learnings contribute to intellectual property (patents) and leverage insights to refine best practices and improve time-to-market for new products.

Qualifications

• Education & Experience: Bachelors degree in Materials Science Polymer Science Chemical Engineering or related field with 10 years of industry experience (or 5 years experience with advanced degree (Masters or Ph.D.) in new product development R&D or process engineering roles. Demonstrated experience in polymer film extrusion and flexible packaging conversion processes is highly desired especially for medical or pharmaceutical packaging applications.
• Medical Packaging & Regulatory Knowledge: Strong knowledge of medical device packaging requirements and standards (e.g. ISO 11607 ISO 13485 FDA regulations). Familiarity with sterilization processes (EtO radiation etc.) biocompatibility considerations. Experience with risk management and design control in regulated product development (FMEA verification/validation traceability) is a plus.
• Technical & Process Expertise: Hands-on skills in polymer processing and packaging engineering including film extrusion coating/lamination thermoforming sealing and related testing methods. Proficiency in process development and validation (e.g. executing IQ/OQ/PQ) and in applying statistical analysis tools (DOE Minitab or similar) for process optimization and problem solving. Ability to interpret engineering drawings and specifications for precise high-quality components.
• Project Leadership & Collaboration: Proven ability to lead complex projects and coordinate cross-functional teams with minimum guidance. Strong project management skills capable of organizing and driving multiple projects to completion balancing technical depth with timeline and budget constraints. Excellent communication and interpersonal skills with a track record of effective collaboration across R&D manufacturing quality regulatory and commercial teams.
• Innovation & Problem-Solving: Creative thinker with a passion for innovation in materials and processes. Demonstrated success in solving challenging technical problems through analytical thinking and experimentation. Evidence of innovation outputs (such as patents published research or commercialized products) is valued.
• Drive & Adaptability: Self-motivated and results-oriented able to thrive in a dynamic environment. Adaptable and resilient with the ability to manage multiple priorities and adjust to evolving project needs. Committed to continuous learning high-quality work and professional growth.
• Travel Requirements: Willingness to travel up to 20% to support customer collaborations off-site trials or manufacturing activities as needed.