Sr. Product Development Engineer/Director of Engineering (Fort Worth, Texas) Our client, a manufacturer of orthopedics, is currently hiring a Sr. Product Development Engineer, this role will serve as the focal point for R&D and engineering, owning processes for supporting bracing/support design and commercialization of new innovations. Person will need to be a highly skilled Director of Engineering / Senior Product Development Engineer with expertise in orthopedic bracing, supports, and/or soft goods medical devices. The ideal candidate will bring extensive knowledge of materials, textiles, foams, plastics, and composites as well as proficiency in CAD design, technical drawings, and material nesting for manufacturing efficiency. This role will lead the engineering function, working closely with Product Management, Manufacturing, and Operations to deliver innovative, clinically effective, and commercially viable orthopedic solutions. There is growth opportunity for this position to lead the building out of the engineering team as demand continues to grow. This position is critical to advancing product pipeline and ensuring continued leadership in the orthopedic bracing and supports market. ESSENTIAL DUTIES AND RESPONSIBILITIES include the following. Other duties may be assigned. This position will have several functions, and the person filling this position will need to wear multiple hats and work primarily with the development team, but will also interact with Manufacturing, Operations and Quality teams. New Product Development & Project Leadership- Drive multiple simultaneous R&D projects from concept through commercialization. Collaborate with Product Managers on defining clinical needs, functional requirements, and design inputs for both upper and lower extremity products. Oversee prototype design, rapid prototyping (including 3D printing), bench testing, and clinical/wear trials. Develop and document product testing protocols (bench, wear, and durability testing). Manage timelines, resources, and budgets to ensure timely product launches. Maintenance of product size chart. Concept & Design Engineering- Lead innovative design exploration for orthopedic braces, supports, and soft goods. Create and refine CAD models (SolidWorks or equivalent), engineering drawings, and assembly documentation. Apply expertise in textile engineering, pattern development, and nesting optimization for efficient material utilization. Leverage various sources - physical measurements, anthropomorphic databases, competitive equivalents - to confirm optimal sizing recommendations Partner with vendors on advanced materials, lamination, thermoforming, and fabrication techniques. Specification Development & Manufacturing Transfer- Develop detailed specifications, bills of materials (BOMs), and inspection criteria for new products. Collaborate with Manufacturing to establish production processes, QC testing methods, and cost optimization strategies. Ensure smooth transfer from prototype to full-scale manufacturing, including tooling, fixturing, and nesting optimization. Product Field Testing & Post-Market Improvements- Coordinate field testing with clinicians and patients, gathering insights on form, fit, and function. Translate clinical and customer feedback into design refinements and next-generation solutions. Lead Engineering Change Orders (ECOs), corrective actions, and product improvements. Cross-Functional & External Collaboration- Build strong relationships with physicians, orthotists, therapists, vendors, and materials 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: Proficiency in SolidWorks (preferred) or similar solid modeling software; ability to generate and manage detailed 2D drawings, 3D models, assemblies, and tolerances. Patterning & Nesting- Experience with textile pattern development, nesting for material efficiency, and digital cutting/CNC nesting software. Materials Expertise- Strong knowledge of textiles, foams, elastomers, laminates, hookand-loop, plastics, composites, and metal hardware commonly used in orthopedic bracing and supports. Testing & Verification- Familiarity with ASTM/ISO medical device test standards, wear simulation, durability testing, and clinical trial coordination. Documentation- Strong capability in Design History Files (DHFs), design inputs/outputs, V&V reports, and ECO documentation. Prototyping- Hands-on experience with rapid prototyping, sewing, thermoforming, injection molding, and 3D printing. Education- Bachelor’s degree in Mechanical Engineering, Biomedical Engineering, Materials Science, Textile Engineering, or related field required. Master’s preferred. 5+ years (Senior Engineer) or 10+ years (Director level) of product development experience, ideally in orthopedic bracing, supports, prosthetics/orthotics, or medical soft goods. Proven record of bringing multiple medical device products from concept to market. Experience leading cross-functional teams and external vendor relationships. Readiness to lead R&D, product development, and support commercialization of orthopedic bracing innovations in a dynamic manufacturing environment. Bachelor’s degree in Mechanical Engineering, Biomedical Engineering, Materials Science, or related discipline. Preferred: Advanced knowledge of soft bracing technologies and orthopedic product field. Experience working with physicians, customers, and handling joint development projects. This role offers the opportunity to lead the design and commercialization of innovative orthopedic bracing solutions, collaborate with talented teams across R&D, manufacturing, and marketing, and make a direct impact on product development from concept to market. For driven engineers passionate about device innovation and seeing their designs benefit real patients, this is a highly rewarding and multifaceted position waiting for you! As part of our promise to talent, Kelly supports those who work with us through a variety of benefits, perks, and work-related resources. Kelly offers eligible employees voluntary benefit plans including medical, dental, vision, telemedicine, term life, whole life, accident insurance, critical illness, a legal plan, and short-term disability. As a Kelly employee, you will have access to a retirement savings plan, service bonus and holiday pay plans (earn up to eight paid holidays per benefit year), and a transit spending account. 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