Foam Process Engineer

Foam Process Engineer

From Chemistry to Quality-Engineer What's Possible!

Location: Morgantown, PA

Your Impact - Big and Bold!

Put your process expertise to work where it makes an impact.

As a Foam Process Engineer, you'll optimize polyurethane foam production processes, troubleshoot equipment and material challenges, and use data to drive improvements in quality, consistency, safety, and productivity.

Working hands-on with resin and isocyanate systems, you'll partner across Manufacturing, Quality, and Engineering to solve problems and continuously improve performance.

What a Day in Your Life Looks Like:


* Process Control: Monitor and optimize polyurethane foam dispensing and mixing processes, including resin/isocyanate ratios, temperatures, pressures, flow rates, and shot weights.



* Equipment Performance: Audit foam processing equipment, troubleshoot issues with Maintenance, and establish preventive maintenance and calibration standards.



* Quality Assurance: Ensure foam meets established density, adhesion, dimensional stability, fill, and performance requirements.



* Root Cause & CAPA: Investigate foam defects-including voids, shrinkage, adhesion, density, fill, and delamination issues-and implement effective corrective and preventive actions.



* Process Optimization: Improve formulations, application methods, and process parameters to increase yield, material utilization, cycle time, scrap performance, and process capability.



* Data & Validation: Analyze production and quality trends, conduct capability studies, and support process validation activities.



* Materials & Suppliers: Partner with suppliers to evaluate raw material performance, resolve resin and isocyanate issues, and qualify new chemicals, suppliers, and equipment.



* New Product Support: Provide foam process expertise for new product development, trials, and manufacturing implementation.



* Documentation & Compliance: Maintain SOPs, work instructions, control plans, specifications, and quality records while ensuring compliance with chemical-handling and EHS requirements.



* Technical Leadership: Serve as the polyurethane foam subject matter expert, providing hands-on troubleshooting, training, and technical support to Production, Maintenance, and Engineering teams.

What You Bring to the Table:


* Education & Experience: Bachelor's degree in Chemical, Mechanical, Manufacturing, Materials Engineering, or a related technical field preferred; equivalent education and relevant experience considered.



* Foam Process Expertise: 5+ years of experience with polyurethane foam systems, chemical processing, or automated dispensing equipment preferred.



* Polyurethane Knowledge: Understanding of polyurethane chemistry, resin/isocyanate systems, and foam manufacturing processes.



* Equipment & Controls: Experience with meter-mix-dispense systems, PLC-controlled equipment, and process monitoring, including troublesh...