Sr. R&D Engineer - Simulation & Modeling

Company: Align Technology
Location: Morrisville
Posted on: February 21, 2026

Job Description:

Job Description Job Description Description This position is ideal for senior-level R&D engineers specializing in Simulation and Modeling to join the Process Modeling team within Product Research Engineering as a Sr. R&D Engineer - Simulation & Modeling. In this role, you will lead the development of advanced manufacturing technologies by applying innovative finite element modeling and machine learning techniques to optimize and understand additive manufacturing processes. Your work will directly enhance the production of dental and orthodontic devices and play a critical role in shaping Align Technology’s next-generation products and driving future success. Role expectations Lead the cutting-edge 3D printing technologies by leveraging innovative finite element models and machine learning approaches to optimize and understand the additive manufacturing process, enhancing the production of dental and orthodontic devices. Lead the machine learning projects for orthodontic system design and manufacturing, from initial data analysis and model development to optimization, deployment, and ongoing monitoring, leveraging massive clinical research database. Lead the development of a state-of-the-art finite element analysis (FEA/FEM) platform of orthodontic systems leveraging cutting edge computational algorithms. Lead the development of robust methods for difficult-to-model conditions leveraging advanced commercial FEA/FEM software. Work cross-functionally with the software team to deploy computational models to very large scales, with design team to integrate model-driven components into the product, with materials and process team to calibrate physical models, and with clinical team to run studies for model validation. Work independently to develop and evaluate new products/solutions or to adapt and improve existing ones using computational modeling and physical experiments. Design, build, and verify test hardware, software, and systems as needed. Define and conduct procedures for bench top testing to evaluate product performance, including efficacy, reliability, verification, and validation, as needed. Work with clinical team to conduct pilot studies and other investigations. Perform and document work in accordance with FDA/ISO regulations, including test protocols, test results, and other requirements. Communicate with professionals in the field at all levels and transition information into product improvement. Provide general engineering support in R&D. What we're looking for Education: MS 6 years or PhD 3 years in Biomedical/Mechanical/Computer Science/Engineering, Statistics or other related degrees/equivalent work experience. Experience and Skills: 5 years with hands-on experience in structural FEA/FEM with simulation software, such as ABAQUS, ANSYS, Comsol, Radioss, etc. 5 years coding experience with programming languages such as Python, MATLAB, C/C++ or Fortran. 5 years with data processing and visualization libraries such as numpy, pandas, matplotlib, VTK, etc. Hands-on experience in machine learning using traditional or deep models, such as scikit-learn, PyTorch, TensorFlow, xgboost, etc. Theoretical and experimental background in structural mechanics, biomechanics, material characterization, and finite element analysis. Communication: Excellent presentation and communication skills. Teamwork: Ability to work both independently and collaboratively. Experience with additive manufacturing technologies and processes. Experience with material (e.g., polymer) characterizations. Experience with 3D modeling tools, such as SolidWorks, Rhinoceros, and HyperMesh. Experience with biomedical research or medical device industry. Experience with numerical optimization. Experience with cloud computation. Pay Transparency If provided, base salary or wage rate ranges are the range in which Align reasonably expects to set a candidate’s pay for the posted position. Actual placement depends on the individual skills and experience level of a candidate plus the total compensation and equity across team members. For other locations outside of the primary location, the base salary range will be adjusted geographically. For Field Sales roles, the salary listed is the base pay only and does not include the applicable incentive compensation plan. A cost of living adjustment may be added to base pay for higher cost areas in the U.S. Our internship hourly rates are a standard pay determined based on the position and your location, year in school, degree, and experience. General Description of All Benefits We are pleased to provide a general description of the benefits Align offers to full-time employees in this position. Family Benefits. Align offers employees and their eligible dependents medical (with a Health Savings Account option for some plan offerings), dental, and vision in accordance with those plans. Align also offers to employees: Discounts on Invisalign and Vivera to employees and their eligible dependents after 90 days of employment Back-up Child/Elder Care and access to a caregiving concierge Family Forming Benefits – Available to Employees, and their spouse or domestic partner, covered under one of Align’s health plans Breast Milk Delivery and Lactation Support Services Employee Assistance Program Hinge Health Virtual Physical Therapy – Available to all employees and eligible dependents (age 18) enrolled in an Align medical Plan Employee benefits. Align offers its employees: Short-term and long-term disability insurance in accordance with those plans. Basic Life Insurance and Accidental Death and Dismemberment. Voluntary Supplemental Life Insurance for Employee, Spouse/Domestic Partner, and Child(ren) are available for purchase in accordance with those plans. Flexible Spending Accounts – Employees may be eligible to participate in a health care account (including a limited health FSA if enrolled in a HDHP), dependent care account, and a pre-tax commuter benefit plan. 401k plan (with a discretionary Company match of 50% up to 6% of eligible earnings up to a maximum match of 3%.). Employer match vests after two years – 25% year one and 100% at year two. Align offers traditional, Roth, and after-tax options. Employee Stock Purchase Program (Employees must work 20 hours or more and be employed on purchase date to be eligible). Paid vacation of up to 17 days during the first full year of employment (currently accrued at the rate of 5.24 hours each pay-period), which carries over to a maximum cap of 30 days. Annual paid vacation time accrual increases based on tenure. Both exempt and non-exempt employees who work 32 hours or more per week receive prorated vacation accrual based on their regularly scheduled work hours and tenure. Sick time is accrued throughout the year at the rate of one hour for every thirty worked. Employees can carry over unused sick leave each year, up to a maximum balance of 80 hours. 11 Company-designated paid holidays throughout the year. If employed for at least 12 consecutive months, Align will grant up to 6 weeks of paid Parental Leave. If employed for less than 12 consecutive months, Align will grant up to 4 weeks of paid Parental Leave. All parental leave must be completed within one year of the birth or placement of the child. Parental leave is in addition to any state and/or local parental leave benefits. Three days of paid bereavement leave. In some cases, due to travel the amount of paid leave may be extended to 5 paid days off. To the extent applicable state or local law offers more generous benefits, Align complies with any such law. Non-exempt employees will receive full pay for up to 10 days of jury duty. Exempt employees will receive their full salary during any week they serve and perform any work. Other insurance such as legal, critical illness, voluntary accident, long-term care, auto, home and pet insurance are available for purchase. To the extent applicable state or local law offers more generous benefits, Align complies with any such law.

Keywords: Align Technology, Raleigh , Sr. R&D Engineer - Simulation & Modeling, Engineering , Morrisville, North Carolina