Materials & Process Engineer

Do you thrive in a dynamic, high-energy, customer-focused environment?

Are you passionate about using state of the art materials and processes to develop sponsor solutions?

Are you excited about researching new materials to improve product performance?

Do you have a broad background in polymeric materials and processing?

If so, we're looking for someone like you to join our team at APL!

We are seeking an experienced Materials and Process Engineer to support the Mechanical Fabrication Group at APL. In this role, you will lead the development, troubleshooting, and hands-on implementation of polymeric resins, adhesives, coatings, and elastomeric materials across all mission areas. You will work closely with APL partners and multidisciplinary design, fabrication, and quality teams to ensure robust, manufacturable solutions. As a recognized materials expert, you will identify opportunities for innovative application of polymer technologies in new and ongoing programs and serve as a technical resource to APL staff in delivering the highest-quality products.

As a Materials and Process Engineer you will:

• Provide technical leadership in the selection, development, qualification, and implementation of polymer-based materials and bonding processes for complex hardware systems. You will be expected to possess an understanding of polymers and processing-performance interactions for structural and non-structural adhesives, polymeric coatings, and elastomeric materials. This role supports the full product lifecycle, from early concept development and material down-selection through fabrication, testing, qualification, and sustainment.
• Lead the design and execution of adhesive bonding processes for metallic, composite, ceramic, and polymer substrates. This includes defining surface preparation methods, adhesive selection, bondline design, fixturing concepts, cure schedules, and environmental controls. You will develop and author detailed process specifications, work instructions, and acceptance criteria, and provide hands-on support during fabrication of bonded assemblies. Example work includes qualifying structural epoxy bonds for load-bearing assemblies, developing elastomer-to-metal bonds for vibration isolation or sealing applications, and troubleshooting bond failures through root-cause analysis and corrective action.
• Apply advanced knowledge of polymeric coatings and elastomers to address environmental protection, durability, and functional performance requirements. This may involve developing or qualifying coatings for corrosion protection, abrasion resistance, chemical exposure, or thermal management, as well as selecting and processing elastomers for sealing, damping, or encapsulation. Responsibilities include defining material formulations, processing parameters, and application methods such as spray, dip, cast, or mold-in-place operations, and evaluating performance through mechanical, thermal, chemical, and aging test methods.
• Collaborate closely with fabrication technicians, design engineers, and quality personnel to ensure processes are robust, repeatable, and scalable. This includes transitioning laboratory-developed processes to production, mentoring junior engineers, and providing expert guidance during design reviews and failure investigations. As the engineer, you will frequently be engaged in hands-on fabrication activities, process trials, and pilot builds to validate assumptions and refine process controls.
• Stay current with emerging polymer technologies, industry standards, and best practices. This includes engaging with suppliers, evaluating new materials and processes, and contributing to internal capability development. Through technical leadership, rigorous engineering judgment, and a balance of analytical depth and practical fabrication experience, you will ensure that adhesive bonded assemblies, coatings, and elastomeric systems meet demanding performance, reliability, and lifecycle requirements.

You meet our minimum qualifications for this job if you have...

• A Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Materials Science, Physics, or a related field.
• Have at least 8+ years of experience working with different polymeric and elastomeric materials including adhesives, coatings, and other resins.
• Knowledge of materials and mechanical design.
• Strong understanding of polymeric based adhesives and coatings.
• Knowledge of reinforced composite materials and processes.
• Strong understanding of mechanical and qualitative testing for bonded and coated assemblies.
• Experience in bonded assembly process development; and ability to solve common engineering problems including the documentation and communication of the work.
• Strong background of hands-on fabrication.
• Excellent oral and written communications skills.
• Ability to work independently and exercising good technical judgment and communicate effectively while working in a team.
• Ability to travel to field sites to support materials engineering tasking.
• Are able to obtain an Interim Secret level security clearance by your start date and can ultimately obtain a Top Secret security level clearance. If selected, you will be subject to a government security clearance investigation and must meet the requirements for access to classified information. Eligibility requirements include U.S. citizenship.

You go above and beyond our minimum requirements if you...

• Have a MS in Mechanical/Materials Engineering.
• Significant experience with bonded assembly fabrication and processing methods to include pressure curing and post processing methods.
• Experience developing tooling to support component fabrication.

Why Work at APL?

The Johns Hopkins University Applied Physics Laboratory (APL) brings world-class expertise to our nation's most critical defense, security, space and science challenges. While we are dedicated to solving complex challenges and pioneering new technologies, what makes us truly outstanding is our culture. We offer a vibrant, welcoming atmosphere where you can bring your authentic self to work, continue to grow, and build strong connections with inspiring teammates.

At APL, we celebrate our differences of perspectives and encourage creativity and bold, new ideas. Our employees enjoy generous benefits, including a robust education assistance program, unparalleled retirement contributions, and a healthy work/life balance. APL's campus is located in the Baltimore-Washington metro area. Learn more about our career opportunities at http://www.jhuapl.edu/careers.

All qualified applicants will receive consideration for employment without regard to race, creed, color, religion, sex, gender identity or expression, sexual orientation, national origin, age, physical or mental disability, genetic information, veteran status, occupation, marital or familial status, political opinion, personal appearance, or any other characteristic protected by applicable law. APL is committed to providing reasonable accommodation to individuals of all abilities, including those with disabilities. If you require a reasonable accommodation to participate in any part of the hiring process, please contact Accommodations@jhuapl.edu.

The referenced pay range is based on JHU APL's good faith belief at the time of posting. Actual compensation may vary based on factors such as geographic location, work experience, market conditions, education/training and skill level with consideration for internal parity. For salaried employees scheduled to work less than 40 hours per week, annual salary will be prorated based on the number of hours worked. APL may offer bonuses or other forms of compensation per internal policy and/or contractual designation. Additional compensation may be provided in the form of a sign-on bonus, relocation benefits, locality allowance or discretionary payments for exceptional performance. APL provides eligible staff with a comprehensive benefits package including retirement plans, paid time off, medical, dental, vision, life insurance, short-term disability, long-term disability, flexible spending accounts, education assistance, and training and development. Applications are accepted on a rolling basis.