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R&D Engineer

R&D Engineer

Kelly CPADallas, TX, United States
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Job details

Job ID : 9976871, 45020873

Job Title : R&D Engineer

Location : DFW Airport, TX

Business Line : Direct Hire, Permanent, Benefits from Day 1

Target Salary : $90000-$110,000 base, dependent on experience

Direct Reports : 0

Travel : 0%

Onsite : Yes

Sponsorship : No. Only US Citizens and green card holders at this time.

Position Overview

The R&D Engineer will lead the design, development, and commercialization of innovative orthopedic products, including braces, supports, and soft goods. This role requires strong technical expertise, hands-on prototyping skills, and the ability to manage multiple projects from concept through market launch. The engineer will collaborate cross-functionally and with external partners to ensure products meet clinical needs, quality standards, and business goals.

Essential Duties & Responsibilities

New Product Development & Project Leadership

  • Drive multiple R&D projects from concept through commercialization.
  • Partner with Product Management to define clinical needs, functional requirements, and design inputs.
  • Oversee prototype design, rapid prototyping (including 3D printing), bench testing, and clinical / wear trials.
  • Develop and document testing protocols (bench, wear, durability).
  • Manage timelines, resources, and budgets to ensure on-time launches.

Concept & Design Engineering

  • Lead design exploration for orthopedic devices and soft goods.
  • Create and refine CAD models (SolidWorks or equivalent), drawings, and assembly documentation.
  • Apply expertise in textile engineering, pattern development, and nesting optimization for material efficiency.
  • Collaborate with vendors on advanced materials, lamination, thermoforming, and fabrication techniques.

    • Specification Development & Manufacturing Transfer

  • Develop specifications, bills of materials (BOMs), and inspection criteria.
  • Work with Manufacturing to establish production processes, QC testing methods, and cost-optimization strategies.
  • Ensure smooth transfer from prototype to manufacturing, including tooling, fixturing, and nesting optimization.

    • Product Field Testing & Post-Market Improvements

  • Coordinate field testing with clinicians and patients; capture insights on form, fit, and function.
  • Translate feedback into design refinements and next-generation solutions.
  • Lead Engineering Change Orders (ECOs), corrective actions, and product improvements.

    • Cross-Functional & External Collaboration

  • Build relationships with clinicians, orthotists, therapists, vendors, and suppliers.
  • Benchmark competitor products and incorporate findings into development.
  • Provide internal product training and technical support to cross-functional teams.

    • Required Knowledge, Skills & Abilities

    Technical & Engineering Skills

  • CAD & Design Tools : SolidWorks (preferred) or equivalent for 2D drawings, 3D models, and assemblies.
  • Patterning & Nesting : Experience with textile pattern development and digital cutting / CNC nesting software.
  • Materials Expertise : Knowledge of textiles, foams, elastomers, laminates, plastics, composites, and hardware used in orthopedic products.
  • Testing & Verification : Familiarity with ASTM / ISO standards, wear simulation, durability testing, and clinical trial coordination.
  • Documentation : Skilled in DHFs, design inputs / outputs, V&V reports, and ECO documentation.
  • Prototyping : Hands-on with rapid prototyping, sewing, thermoforming, injection molding, and 3D printing.

    • Core Competencies

  • Strong analytical and problem-solving skills.
  • Excellent communication skills (written and verbal).
  • Ability to balance speed-to-market with safety, compliance, and quality.
  • High attention to detail and quality standards.
  • Proven ability to work cross-functionally and lead teams effectively.

    • Qualifications

  • Education : Bachelor's degree in Mechanical, Biomedical, Materials Science, or Textile Engineering (Master's preferred).
  • Experience :

    • 5+ years (Senior Engineer) or 10+ years (Director-level) in product development, preferably in orthopedic bracing, supports, prosthetics / orthotics, or medical soft goods.

  • Proven record of taking multiple medical device products from concept to market.
  • Experience leading cross-functional teams and managing vendor relationships.

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    Rd • Dallas, TX, United States

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