Senior Researcher - Plastic Materials

USG is an industry-leading manufacturer of building products and innovative solutions. For over 120 years, Chicago-based USG has developed award-winning wall, ceiling, flooring, sheathing, and roofing products that enable customers to build outstanding spaces where people live, work, and play. With over 8,700 employees across North America and operations around the world, we are steadfastly committed to our core values: safety, innovation, quality, integrity, service, diversity, and efficiency.

We’re big enough that our professionals have the resources to make a difference, yet small enough that you’re not just a number. You’ll work on key initiatives and build strong relationships across the company that will position USG for growth into the future.

USG offers work-life balance, specialist and general/managerial career paths, promotion from within, exceptional benefits, and incredible long-term career opportunities for the right professional. Each year, we have hundreds of employees who celebrate milestone anniversaries with us.

Position Overview:

We are seeking a knowledgeable and experienced Plastic Extrusion Materials Expert to oversee material selection, formulation development, and process optimization within our extrusion operations. This position reports directly to the Laboratory Director and collaborates with multidisciplinary teams focused on construction-related products. The successful candidate will drive advancements in polymer compounding, ensure superior product performance, resolve process challenges, and work closely with production, quality, and business units to deliver industry-leading extruded components.

Job Functions

• Lead the assessment and selection of thermoplastic resins, additives, and fillers to fulfill specified mechanical, thermal, and aesthetic requirements.
• Develop and optimize material formulations through laboratory trials utilizing DSC, TGA, Rheology, and other advanced analytical techniques.
• Collaborate with extrusion engineers to refine process parameters—including temperature, screw configuration, back pressure, and throughput—to achieve consistent quality.
• Diagnose and address material-related defects such as surface imperfections, dimensional inconsistencies, and melt fracture, implementing effective corrective measures.
• Establish standardized protocols for material testing and acceptance criteria, ensuring thorough documentation and traceability.
• Engage with suppliers to qualify new polymers, negotiate technical specifications, and manage trial shipments.
• Support product innovation by evaluating emerging polymer chemistries and initiatives related to sustainability, such as bio-resins and recycled content.
• Provide technical training and mentorship to production and quality personnel regarding material behavior and best practices.

Education and Qualifications

• PhD or Master’s degree in Polymer Science, Materials Engineering, or a related discipline.
• A minimum of 5 years’ experience (PhD) or 10 years’ experience (Master’s) in plastic extrusion development or materials laboratory settings.
• Comprehensive understanding of thermoplastic extrusion processes, screw designs, and troubleshooting techniques.
• Proficiency in the operation of polymer characterization instruments, including DSC, TGA, rheometer, and melt flow indexer.
• Strong analytical and problem-solving capabilities, with demonstrable experience in Design of Experiments (DOE) and statistical process control methodologies.
• Excellent communication skills and proven ability to collaborate across functions.
• Willingness and ability to travel to manufacturing plants and customer sites as necessary.

Rate of pay may be adjusted based on the qualifications and experience of the candidate.

USG employees enjoy a number of benefit options for themselves and their families. These include two medical insurance options, as well as vision and dental coverage. The cost of these optional programs varies based on coverage level - employees generally pay 25% of the monthly premium cost, USG pays the rest. These coverage options are offered on the first day of employment with no waiting period.

Additionally, USG employees enjoy both a 401(k) Investment Plan with company match and a pension plan. Beyond these main features, employees may also choose from a number of additional programs like life insurance, accident insurance, legal insurance, even pet insurance, just to name a few. USG also offers Quarterly (hourly) / Annual (salary) bonus potential for all employees based on performance metrics tied to safety, quality, and productivity.  USG also provides employees with paid time off and paid holidays.

Since 1902, Chicago-based USG has been a lead