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Senior Staff Consultant - Materials: Polymers & Plastics

Engineering Systems, Inc. (ESI)
110000.00 To 130000.00 (USD) Annually
United States, Illinois, Aurora
Sep 02, 2025
ESi's polymer materials practice group is seeking an engineer to join our Aurora office. Ideal candidate will have past training and experience in failure analysis and forensic consulting specific to investigation involving polymer materials and plastic products. Key experience required are in the area of fractography, material characterization, product failure analysis, mechanical testing, long-term creep and fatigue testing of polymers, and chemical compatibility testing of polymers. Individual will be responsible for execution of technical projects by performing testing and root-cause failure analysis investigations using various polymer characterization equipment. Project management of large and small scale client engagements related to technical subjects in support of industrial consulting projects, insurance investigations, litigation analysis will be required. Candidate must be efficient at accomplishing work within prescribed time frame and have exceptional technical writing skills.

Key Responsibilities:

  • Conducts and directs laboratory analysis using optical microscopes, scanning electron microscope, differential scanning calorimeter (DSC), Fourier Transform Infrared (FTIR) microscopy, and Thermogravimetric Analyzer (TGA).
  • Conduct ASTM standard based tests for tensile, flexural, compression properties using mechanical testing machine.
  • Conducts and directs field investigations as needed.
  • Performs technical analysis, calculations, testing and research.
  • Prepares technical reports, provides professional opinions and advice for clients, or others.
  • Confers with project personnel to provide technical advice and to resolve problems.
  • Testifies in court and provides deposition testimony, if requested.
  • Establishes work plan and staffing for each phase of project and arranges for recruitment or assignment of project personnel.
  • Confers with project staff to outline work plan and to assign duties, responsibilities, and scope of authority.
  • Directs and coordinates project activities and personnel to ensure project progresses on schedule and within prescribed budget.
  • Reviews, or in some cases formulates status reports prepared by project personnel and modifies schedules or plans as required.
  • Conduct technical analysis and investigations pertaining to materials with a focus on polymer science.
  • Technical evaluations and testing focused on product design, manufacturing, material selection, and chemical compatibility and long- term material properties.
  • Verbal and written communication with clients, conducts well-developed and well-prepared client presentations.
  • Coordinates project activities with staff and clients, with proper internal reviews.
  • Works with Marketing to identify potential clients and strategies to build client base.

Education Requirements:

  • Bachelor of Polymer Science/engineering degree or equivalent from accredited institution required.
  • Advanced degree (PhD) preferred.

Experience Requirements:

  • 3 to 5 years of related experience and/or training; or equivalent combination of education and experience.

Certificates, Licenses, Registrations:

  • Professional engineering license, (PE) or equivalent preferred.

Computer Skills:

  • Familiar with Microsoft Word, Excel, Outlook, Powerpoint.
  • Proficient at keyboarding to produce written communications and reports in a timely manner.
  • Knowledge with technical and modeling software, such as MathCad, Autocad, or similar programs is preferred.

Other Skills/Abilities or Other Qualifications:

  • Strong familiarity application of industry standards, chemical analysis, mechanical testing, and service life predictions of products.
  • Willingness and ability to actively market self and ESi to outside clients.
  • Willingness and ability to travel locally and nationally for inspections, client meetings, conferences, etc as needed.

Physical Demands:

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. While performing the duties of this job, the employee is occasionally required to stand, walk, and sit for extended periods of time. Able to climb ladders and lift up to 50 lbs. Must be able to work in small spaces. Must be able to kneel, squat, or bend.

Work Environment:

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of the job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. The noise level in the work environment is usually moderate. Must be able to work outdoors in hot/cold weather conditions.

To all recruitment agencies: ESi does not accept unsolicited resumes from search firms or agencies. Any resume submitted to any employee of ESi without a prior written search agreement will be considered unsolicited and the property of ESi. Please, no phone calls or emails.

It is the policy of ESI, as an equal opportunity employer, to attract and retain the best qualified individuals available, without regard to race/ethnicity, color, religion, national origin, gender, sexual orientation, age, disability, or veteran status. ESI is committed to recruiting, hiring, and promoting people with disabilities, as well as veterans. If you need assistance with completing the electronic application, please email your request to employment@engsys.com

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