Staff Engineer, Additive Manufacturing

About Orthopaedics

Fueled by innovation at the intersection of biology and technology, we’re developing the next generation of smarter, less invasive, more personalized treatments. Are you passionate about improving and expanding the possibilities of Orthopaedics? Ready to join a team that’s reimagining how we heal? Our Orthopaedics teams help keep more than 6 million people moving each year while delivering clinical and economic value to surgeons and healthcare systems. Our teams build solutions for joint reconstruction; trauma and craniomaxillofacial; sports, extremities, and elective foot and ankle; spine; and robotics and digital surgery. Your unique talents will help patients on their journey to wellness. Learn more at https://www.jnj.com/medtech.

We are searching for the best talent for a

Staff Engineer, Additive Manufacturing, to support spine-focused medical device R&D through end-to-end titanium laser powder bed fusion (LPBF) prototyping and product development. This position is hybrid based out of our Raynham, MA office location.

Johnson & Johnson announced plans to separate our Orthopaedics business to establish a standalone orthopaedics company, operating as DePuy Synthes. The process of the planned separation is anticipated to be completed within 18 to 24 months, subject to legal requirements, including consultation with works councils and other employee representative bodies, as may be required, regulatory approvals and other customary conditions and approvals.

Should you accept this position, it is anticipated that, following conclusion of the transaction, you would be an employee of DePuy Synthes, and your employment would be governed by DePuy Synthes employment processes, programs, policies, and benefit plans. In that case, details of any planned changes would be provided to you by DePuy Synthes at an appropriate time and subject to any necessary consultation processes.

Purpose:

The Staff Engineer will support the development and optimization of Additive Manufacturing processes and products for R&D. Specifically, this role will own the additive manufacturing loop—from defining and creating the build files, identifying ideal print slicing specifications, some printer operation activities, and structured feedback into subsequent design iterations. This position is best suited for an engineer who is comfortable operating metal AM equipment, applying DfAM principles, and working within a regulated medical device development environment.

A key focus of the position is expanding the team’s AM capabilities, with the Staff Engineer collaborating closely with cross functional teams—including Manufacturing Innovation, Quality, Validation, and Maintenance The role involves developing and supporting value stream projects, ensuring alignment, standardization, and best practice implementation across the network.

You will be responsible for:

• Lead end to end Additive Manufacturing process development and industrialization for complex processes and New Product Introductions (NPI), ensuring scalable, robust, and validated manufacturing processes.
• Create, modify, and optimize LPBF build files for titanium medical implants including:
  • Part orientation and nesting strategy
  • Support generation and optimization to balance surface quality and removability
  • Thermal management considerations for distortion-sensitive implant geometries.
• Review CAD models for printability, manufacturability, and risk, providing DfAM feedback tailored to spine implants (e.g., lattice development, fixation features, anatomical surfaces).
• Maintain build documentation consistent with R&D and design control expectations.
• Be familiar with LPBF Printer Operations including
  • Machine setup, calibration, and pre-build checks
  • Titanium powder handling, recycling, and traceability
  • Build execution, monitoring, and first-level troubleshooting
  • Part Removal, Post-Processing & Inspection
• Identify print anomalies relevant to implant manufacturing (distortion, support failure, surface defects).
• Support continuous improvement of AM processes, SOPs, and internal best practices for medical titanium printing.
• Perform preliminary inspection and documentation:
  • Visual inspection and defect classification
  • Basic dimensional verification
  • Identification of risks impacting downstream testing (mechanical, fatigue, coating, etc.)
• Prototype Feedback & R&D Iteration
• Provide clear, structured feedback from each build to inform:
  • Design revisions
  • Build orientation and support changes
  • Parameter and layout refinements
  • Partner closely with Spine R&D engineers, Designers, and manufacturing teams to accelerate prototype learning cycles.
• Lead cost reduction and productivity initiatives (scrap/rework reduction, throughput improvements, consumables optimization) with measurable savings and sustainability impacts.
• Provide technical mentorship to engineers and technicians, champion continuous improvement culture, and support capability development across the organization.

Qualifications:

Required Qualifications & Experience

• Bachelor’s degree or equivalent experience in Engineering (or equivalent).
• Demonstrated 4-6 years of experience in a relevant engineering role
• Demonstrated ability in additive manufacturing/process engineering
• 3+ years of hands-on experience with metal additive manufacturing, preferably LPBF.
• Demonstrated experience creating metal AM build files (support design, part orientation, part slicing specifications, part layout).
• Experience operating industrial LPBF printers, from build file setup to completed build.
• Strong experience in structured problem solving and root cause analysis.
• Excellent technical content skills (specifications, validation protocols, change control).
• Experience leading multi-functional teams and influencing collaborators at multiple levels.
• Proven experience supporting NPI, scale‑up and transfer activities.

Preferred Qualifications & Experience (Nice to Haves)

• Experience specifically with titanium spinal implants or orthopedic medical devices.
• Familiarity with LPBF printing platforms, experience with 3DS printing platforms preferred
• Experience with build prep software such as 3Dxpert, Materialise Magics, EOSPRINT, Netfabb, nTopology, or similar.
• Exposure to post-processing steps commonly used in medical devices (heat treatment, HIP, surface finishing).
• Familiarity with calibration, maintenance practices and working closely with in‑house maintenance teams.
• Knowledge of regulatory requirements and submissions applicable to medical device manufacturing.
• Prior experience mentoring/leading emerging engineers or small technical teams.

Johnson & Johnson is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, age, national origin, disability, protected veteran status or other characteristics protected by federal, state or local law. We actively seek qualified candidates who are protected veterans and individuals with disabilities as defined under VEVRAA and Section 503 of the Rehabilitation Act.

Johnson & Johnson is committed to providing an interview process that is inclusive of our applicants’ needs. If you are an individual with a disability and would like to request an accommodation, please contact us via https://www.jnj.com/contact-us/careers or contact AskGS to be directed to your accommodation resource.

Required Skills:

Manufacturing Process Engineering, Problem Solving, Product Development

Preferred Skills:

NPI Management, Regulatory Requirements

The anticipated base pay range for this position is :

$109,000.00 - $174,800.00

Additional Description for Pay Transparency:

Subject to the terms of their respective plans, employees are eligible to participate in the Company’s consolidated retirement plan (pension) and savings plan (401(k)).

Subject to the terms of their respective policies and date of hire, employees are eligible for the following time off benefits:

Vacation –120 hours per calendar year

Sick time - 40 hours per calendar year; for employees who reside in the State of Colorado –48 hours per calendar year; for employees who reside in the State of Washington –56 hours per calendar year

Holiday pay, including Floating Holidays –13 days per calendar year

Work, Personal and Family Time - up to 40 hours per calendar year

Parental Leave – 480 hours within one year of the birth/adoption/foster care of a child

Bereavement Leave – 240 hours for an immediate family member: 40 hours for an extended family member per calendar year

Caregiver Leave – 80 hours in a 52-week rolling period10 days

Volunteer Leave – 32 hours per calendar year

Military Spouse Time-Off – 80 hours per calendar year

Please use the following language:

For additional general information on Company benefits, please go to: - https://www.careers.jnj.com/employee-benefits