R&D Associate - Advanced Manufacturing and Characterization of Polymer Composites

Requisition Id 16652 

 

Overview:

We are seeking an R&D Associate Staff – Advanced Manufacturing and Characterization of Polymer Composites who will lead and execute research focused on experimental, computational modeling, and the establishment of processing–structure–property relationships for advanced polymer composite systems. The successful candidate will support the development of predictive tools, digital manufacturing capabilities, and data-driven approaches to accelerate the design, optimization, and scale-up of high-performance composite manufacturing processes. This position resides in the Composites Innovation Group within the Manufacturing Science Division, Energy Science and Technology Directorate, at Oak Ridge National Laboratory (ORNL).

 

Major Duties/Responsibilities:

• Conduct independent and team-based research on processing–structure–property relationships to enable the integration of novel polymer composite materials into advanced manufacturing workflows.
• Develop and apply high-rate manufacturing processes for composites including injection molding (IM), compression molding (CM), thermoforming, and sheet molding compound (SMC).
• Lead and manage multifunctional materials research projects, including planning, execution, and delivery of technical milestones.
• Conduct research on high-rate manufacturing of polymer composites for industrially relevant applications.
• Lead the development and application of computational modeling, simulation, and data-driven tools for advanced composite manufacturing processes and structures.
• Develop software, coding frameworks, and digital workflows for process modeling, material behavior prediction, design optimization, and manufacturing decision support using languages such as Python, MATLAB, C++, or similar platforms.
• Perform research on physics-based, data-driven, and hybrid modeling approaches for composite manufacturing processes, including additive manufacturing, joining, molding, and multifunctional materials.
• Support the development of digital twins, machine learning, artificial intelligence, and predictive analytics capabilities for advanced manufacturing systems and composite structures.
• Design and execute experimental validation activities to verify and improve modeling and simulation tools, including correlation of mechanical, thermal, microstructural, and manufacturing process data.
• Utilize advanced characterization and testing methods to generate validation datasets and establish processing-structure-property-performance relationships for composite materials and manufacturing processes.
• Perform failure analysis and process–property correlation to guide material and process improvements.
• Maintain high scientific productivity through collaboration, innovation, and research excellence.
• Engage with senior scientists, academic partners, and industry collaborators, and prepare technical reports, publications, and invention disclosures.
• Ensure compliance with environmental, safety, health, and quality program requirements.
• Deliver ORNL’s mission by aligning behaviors, priorities, and interactions with our core values of Impact, Integrity, Teamwork, Safety, and Service. Promote equal opportunity by fostering a respectful workplace – in how we treat one another, work together, and measure success.

 

Basic Qualifications:

• A PhD in Materials Science and Engineering, Mechanical Engineering, Polymer Science, Aerospace Engineering, or a related discipline.
• 2 years of post-PhD research or equivalent industrial R&D experience in polymer composites or advanced manufacturing.
• Proven ability to lead technical tasks and contribute to multidisciplinary research programs.

 

Preferred Qualifications:

• Experience leading experimental development, test planning, and validation strategies for composite manufacturing processes.
• Experience with high-rate composite manufacturing and scale-up research.
• Experience with injection molding, compression molding, thermoforming, SMC, and overmolding processes.
• Strong programming and software development skills (e.g., Python, MATLAB, C++, Julia, or similar) for engineering analysis, process modeling, data analytics, and automation.
• Experience with finite element analysis (FEA), process simulation, digital t