Sr. Materials Engineer, R&D Core Materials

Department: Research & Development

Align Technology, Inc. is seeking a Senior Materials Engineer with deep expertise in polymer science, sustainability, material compatibility, and medical device packaging to lead complex, cross-functional projects spanning orthodontic accessory and ancillary product compatibility, recycled materials innovation, and advanced packaging development.

This role serves as a technical leader and subject-matter expert (SME) who defines testing strategy, establishes technical direction, and partners across the organization to translate material innovations into scalable, compliant, and sustainable product solutions.

You will collaborate across R&D, eCommerce, Manufacturing, Regulatory, Quality, Legal, and Supply Chain to deliver robust material solutions that enable Align’s growth and sustainability goals.

Role Expectations

• Lead and own material selections and studies for orthodontic accessory and ancillary products to ensure safety, functionality with Invisalign orthodontic appliances, and packaging.
• Drive the development of circular-material technologies by transforming recycled polymers into high-performance, qualified applications.
• Design, evaluate, and optimize medical and consumer packaging for performance, manufacturability, and sustainability in accordance with ISO 11607 and ASTM/ISTA standards.
• Design and perform standard and customized polymer characterization (thermal, mechanical, rheological, spectroscopic) and long-term reliability evaluations.
• Define and approve material specifications; author validation protocols and reports documentation per Design Control and QMS requirements.
• Lead collaboration with internal teams and external partners to evaluate, qualify, and scale sustainable materials and packaging solutions globally.
• Support chemical-compliance and biocompatibility evaluations to ensure regulatory readiness and provide data for product filings.
• Translate complex test results into clear technical reports, risk assessments, and strategic recommendations that guide product and business decisions.
• Mentor and coach engineers and technicians to strengthen experimental design, data integrity, and sustainability best practices across the materials function.

What We're Looking For

• M.S., or Ph.D. degree in Polymer Science, Materials Science, Chemistry, Chemical Engineering, or related discipline.
• 8+ years of R&D experience involving polymers, packaging, or medical devices.
• Proven expertise in polymer characterization, structure–property analysis, and material compatibility evaluation. Must have the technical abilities to apply results to product performance metrics.
• Strong background in sustainability and recycled materials development, including processing, evaluation, and qualification for value-added applications.
• Hands-on experience in packaging materials design, development, and validation for medical or consumer products.
• Excellent technical communication and cross-functional collaboration skills.
• Strong analytical thinking and ability to translate data into practical engineering recommendations.
• Demonstrated ability to manage multiple projects and influence cross-functional stakeholders.
• Demonstrated learning agility, ownership, and a proactive, results-driven mindset.
• Ability to take initiative, follow through, and approach challenges with curiosity and persistence in a fast-paced environment.
• High standards of execution, integrity, and accountability, with a strong commitment to achieving results and goals.

Complementary Skills

• Experience evaluating material interactions for chemical and functional compatibility with medical devices and packaging systems.
• Knowledge of environmental, chemical, and packaging compliance standards, including REACH, RoHS, Prop 65, TSCA, ISO 10993, and ISO 11607.
• Familiarity with sustainable packaging materials, validation methods, and relevant ASTM and ISTA test standards (e.g., ASTM F88, F1980; ISTA 3A).
• Working knowledge of design control, risk management, and validation processes in accordance with ISO 13485 and FDA QSR requirements.

Compensation & Benefits

The compensation for this role is between $149,800 - $206,000 / year. Align Technology offers comprehensive benefits, including medical, dental, vision, 401k with company match, ESPP, paid vacation, sick time, parental leave, and more. Specific benefits are detailed below:

• Discounts on Invisalign and Vivera to employees and their eligible dependents after 90 days of employment
• Back-up Child/Elder Care and access to a caregiving concierge
• Family Forming Benefits – Available to Employees, and their spouse or domestic partner, covered under one of Align’s health plans
• Breast Milk Delivery and Lactation Support Services
• Employee Assistance Program
• Hinge Health Virtual Physical Therapy – Available to all employees and eligible dependents (age 18+) enrolled in an Align medical Plan
• Short-term and long-term disability insurance
• Basic Life Insurance and Accidental Death and Dismemberment
• Voluntary Supplemental Life Insurance for Employee, Spouse/Domestic Partner, and Child(ren)
• Flexible Spending Accounts – including health care, dependent care, and pre-tax commuter benefit plan
• 401k plan (with a discretionary Company match of 50% up to 6% of eligible earnings up to a maximum match of 3%). Employer match vests after two years.
• Employee Stock Purchase Program (Employees must work 20 hours or more and be employed on purchase date to be eligible).
• Paid vacation of up to 17 days during the first full year of employment, increasing with tenure.
• Sick time accrued at one hour for every thirty worked, up to a maximum balance of 80 hours.
• 11 Company-designated paid holidays throughout the year.
• Up to 6 weeks of paid Parental Leave (4 weeks if employed less than 12 months).
• Three days of paid bereavement leave (up to 5 days with travel).
• Jury duty pay.
• Other insurance such as legal, critical illness, voluntary accident, long-term care, auto, home and pet insurance are available for purchase.

Key skills/competency

• Polymer Science
• Materials Science
• Medical Device Packaging
• Sustainability
• R&D Leadership
• Material Compatibility
• ISO 11607
• ASTM/ISTA Standards
• Polymer Characterization
• Design Control