Senior Director of Engineering - Aerosol Jet 3D Printing, Motion Control & Electronics

Description

The Senior Director of Engineering will lead the global engineering organization responsible for the design, development, and industrialization of Aerosol Jet additive manufacturing systems. This executive will drive innovation and best practices across motion control, fluidic delivery, deposition systems, electronics, and embedded controls, ensuring world-class performance, reliability, and manufacturability.

This role requires a strategic technical leader who can guide multi-disciplinary engineering teams, integrate complex subsystems, and partner with manufacturing and outsourced partners to deliver scalable, production-ready solutions for advanced printed electronics and precision additive manufacturing.

Requirements

Key Responsibilities:

Strategic & Technical Leadership

• Define and execute the engineering roadmap for next-generation Aerosol Jet 3D printing systems and subsystems (motion platforms, deposition heads, electronics, and control architecture).
• Lead cross-functional teams in mechatronics, electrical, firmware, and process control engineering.
• Aligning engineering priorities with business goals for performance, yield, cost, and manufacturability.
• Provide technical oversight in fluid dynamics, aerosol generation, atomization, and printhead design.
• Champion engineering best practices for reliability, system integration, and design for manufacturing (DFM/DFA).

System Design & Motion Control

• Direct the design and optimization of precision motion and positioning systems, including linear/rotary stages, servo drives, feedback sensors, and motion controllers.
• Oversee system-level integration between mechanical motion, electronic control, and deposition subsystems to achieve micro-level repeatability and throughput goals.
• Ensure implementation of advanced motion algorithms, trajectory planning, and synchronization with deposition timing for high-accuracy material placement.

Electronics & Embedded Systems

• Guide architecture and development of control electronics, power systems, and embedded firmware for real-time control of Aerosol Jet processes.
• Ensure robust system integration between sensors, motion controllers, PLCs, and user interfaces (HMI/software).
• Oversee design validation, EMI/EMC compliance, and safety certification for global markets.

Operational & Program Management

• Implement stage-gate product development, configuration control, and design verification processes.
• Drive outsourced manufacturing and supplier collaboration for motion subsystems, electronics, and precision assemblies.
• Establish strong partnerships with contract manufacturers, ensuring technical transfer and sustaining support.
• Manage engineering budgets, schedules, and resource allocation across global sites.

People & Organizational Leadership

• Build and mentor a world-class engineering team across hardware, controls, and system integration disciplines.
• Foster a culture of innovation, accountability, and technical excellence.
• Develop engineering leaders capable of scaling with the organization’s growth.

Qualifications:

Education

• Bachelor’s degree in Mechanical, Electrical, or Mechatronics Engineering required.
• Advanced degree (MS/PhD) in relevant field (e.g., Controls, Mechatronics, Applied Physics, or Materials Science) preferred.

Experience

• 15+ years of engineering experience with 7+ years in senior leadership roles within high-precision equipment industries (3D printing, semiconductor tools, inkjet, or industrial automation).
• Understanding and expertise in Aerosol Jet, inkjet printing, or micro dispensing systems, including understanding of atomization, aerosol transport, and deposition control.
• Strong background in motion  control, embedded systems, and precision mechatronics.
• Demonstrated success scaling engineering organizations and transitioning products from R&D to volume manufacturing.
• Experience managing outsourced design and manufacturing partnerships globally.

Skills

• Deep system-level understanding of 3D printing technology and motion control systems, with understanding of automation integration for scaling mass production operations in manufacturing.
• Strong analytical and problem-solving abilities with a focus on design robustness and process stability.
• Effective communicator capable of influencing across technical and executive levels.
• Skilled in risk management, root cause analysis, and process improvement.

Performance Metrics:

• On-time, on-budget delivery of new product introductions (NPI).
• Achieved performance improvements in print resolution, throughput, and reliability.
• Supplier and partner quality metrics.
• Team growth, retention, and cross-functional collaboration outcomes.
• Align with software understanding and operational integration with hardware.