Staff Polymer Engineer

Position Overview

The Staff Polymer Engineer will lead the development and optimization of multilayer polymer films produced through advanced co-extrusion processes that enable Folio’s next-generation optical data storage media.This role provides technical leadership in polymer materials and extrusion processing while working collaboratively with Folio’s internal engineering teams and external polymer processing and extrusion experts. The successful candidate will coordinate development efforts across engineers, equipment suppliers, and external consultants while also learning from and contributing to a team of experienced specialists advancing the multilayer film technology.The position will also collaborate closely with experienced production leadership within the organization, leveraging their expertise in manufacturing scale-up and process implementation as the multilayer film technology transitions from development to production.This position is ideal for an engineer who enjoys working at the intersection of polymer science, rheology, multilayer flow physics, extrusion technology, and materials innovation, and who is excited to help develop a new materials platform from early development through scalable manufacturing.

Key Responsibilities

Multilayer Film Development

• Develop multilayer polymer film structures with tightly controlled layer thickness and optical properties
• Translate optical and system requirements into polymer materials and multilayer film architectures
• Evaluate polymer material systems for optical clarity, refractive index control, and long-term stability
• Work with internal teams and external partners to refine film designs and processing approaches

Co-Extrusion Process Development

• Develop and optimize multilayer co-extrusion processes
• Define processing conditions including:
• Temperature profiles
• Polymer rheology matching
• Flow balancing and layer stability
• Work with extrusion equipment suppliers on feedblock and multilayer die architectures
• Investigate and resolve processing challenges such as:
• Interfacial instability
• Layer distortion
• Optical defects (haze, birefringence)
• Layer thickness variation

Polymer Materials & Rheology

• Characterize polymer rheology and understand its impact on multilayer flow behavior
• Evaluate candidate polymers for process compatibility and optical performance
• Develop material combinations that support stable multilayer processing and optical quality

Process Development & Scale-Up

• Support development of pilot-scale and manufacturing-scale co-extrusion processes
• Contribute to specification and commissioning of multilayer extrusion equipment
• Develop process documentation and best practices for film manufacturing

Cross-Functional Collaboration

• Collaborate with optical, mechanical, and systems engineers to ensure multilayer films meet system requirements
• Work closely with external polymer processing consultants, materials experts, and extrusion equipment suppliers
• Partner with internal production leadership to guide the transition of multilayer film technology from development to scalable manufacturing
• Coordinate technical development across internal teams and external partners to advance Folio’s multilayer film technology

Required Qualifications

• PhD, MS, or BS in Polymer Engineering, Polymer Science, Chemical Engineering, Materials Science, or related field
• 5+ years education / experience in polymer processing, extrusion, or film manufacturing
• Strong understanding of:
• Polymer rheology
• Extrusion processing
• Thermoplastic materials behavior
• Experience with polymer characterization and materials evaluation
• Strong experimental and problem-solving skills
• Ability to work effectively in a collaborative, fast-moving development environment

Nice to Have Qualifications

• Experience with multilayer co-extrusion
• Familiarity with feedblock and multilayer die design
• Experience with optical-grade polymer films
• Experience with polymers such as:
• Polycarbonate (PC)
• PMMA
• PETG
• COC/COP
• Other optical thermoplastics
• Familiarity with polymer flow modeling or extrusion simulation tools
• Experience scaling processes from R&D to pilot or manufacturing environments