Lead Controls Engineer

Company Description PostProcess® Technologies develops automated solutions for the often tedious and labor-intensive third step of additive manufacturing: post-printing. The company delivers comprehensive technology platforms that enable customer-ready 3D-printed parts at scale. As a leader in automated post-printing, PostProcess provides systems for support removal, resin cleaning, surface finishing, and powder removal. These solutions help manufacturers achieve consistent, high-quality results while significantly reducing time-to-market. For more information, visit www.postprocess.com.

Role Description This is a full-time, hybrid Lead Controls Engineer role based in Buffalo, NY, with flexibility for part-time work from home. The Lead Controls Engineer will design, develop, and implement control systems for automated post-printing equipment, including PLC programming, HMI development, and integration of sensors, actuators, and motion control components. This role will oversee system architecture for new products, lead controls-related design reviews, and ensure compliance with safety and regulatory standards. The person in this position will collaborate closely with mechanical, electrical, and software engineering teams to prototype, test, and refine systems, as well as troubleshoot and resolve issues on existing platforms. Responsibilities also include mentoring other engineers, creating and maintaining documentation, and supporting field deployments and customer installations as needed.

1. Technical Leadership & Authority:

• Serve as the technical authority for industrial control systems, electrical architecture, and PCB designs
• Define and enforce controls and electrical design standards, documentation practices, and review criteria
• Provide technical leadership and mentorship to internal engineers and outsourced engineering partners
• Act as a key technical decision-maker across electrical, embedded, and mechanical system boundaries

2. Hands-On Controls & Electrical Design:

• Personally perform hands-on engineering work as required, including:
• Control system architecture and I/O definition
• Wiring diagrams, schematics, and control panel layouts
• PCB schematic updates and design changes
• Execute design updates to support:
• ECOs, cost-down initiatives, supplier changes, and field issues
• Leverage outsourced engineering resources when workload exceeds internal capacity or critical timelines,
• while retaining full technical ownership and approval responsibility

3. Technical Package & Configuration Management:

• Own and maintain complete controls and electrical technical packages, including:
• Schematics, wiring diagrams, and panel layouts
• PCB schematics, layouts, and BOMs
• I/O maps, safety circuits, and interlock definitions
• Lead and execute engineering change orders (ECOs), including:
• Technical impact analysis
• Documentation updates and revision control
• Cross-functional coordination with manufacturing, quality, and supply chain
• Ensure strict configuration discipline across released and in-production electrical and controls designs

4. Quality, Safety, & Reliability Responsibilities:

• Own controls- and electrical-related quality responsibilities, including:
• Verification and validation planning for control systems and PCBs
• Definition of acceptance criteria and test coverage
• Ensure compliance with applicable electrical safety, regulatory, and industry standards (e.g., UL, CE, SGS)
• Partner with Manufacturing and Operations to:
• Identify quality escape risks
• Support root cause analysis (RCA) and corrective actions (CAPA)
• Design systems with consideration for:
• Reliability, serviceability, and real-world operating conditions
• Safety, integrity, and fault detection
• Help establish scalable controls and quality practices with the intent to transition ownership when a dedicated Quality Engineer is added

5. Product Development, Cost Reduction, & Manufacturing Support:

• Drive the development and continuous improvement of control systems and electrical designs across
• products
• Lead cost-reduction initiatives through:
• Component standardization and reuse
• BOM optimization and alternate sourcing
• Design simplification and panel consolidation
• Provide direct engineering support for:
• System integration
• Electrical troubleshooting during production and validation
• Field issue resolution as needed

• 6. Product Development, Cost Reduction, & Manufacturing Support:
• Act as the primary controls and electrical liaison between internal teams and outsourced engineering
• partners
• Collaborate closely with mechanical, software, embedded, and manufacturing teams to ensure
• system-level integration
• Communicate design decisions, risks, and trade-offs clearly to the Director of Engineering
• Maintain clear documentation of design intent, decisions, and changes to ensure long-term product
• continuity
• Performance Metrics
• Accuracy, completeness, and timeliness of released controls and electrical documentation
• Effectiveness of ECO execution and configuration control
• Reduction in electrical and controls-related manufacturing or field issues
• Progress against cost-reduction and reliability improvement goals
• Quality and responsiveness of outsourced engineering deliverables

Skills and Qualifications

Technical Expertise:

• Deep knowledge of industrial control systems, motor drives, and safety circuitry
• Strong hands-on experience with electrical schematics, wiring diagrams, and control panel design
• Experience reviewing and updating PCB schematics, layouts, and BOMs
• Familiarity with applicable regulatory and safety standards (UL, CE, SGS, RoHS, REACH

Leadership and Collaboration:

• Ability to lead through technical authority and ownership
• Experience directing and reviewing outsourced engineering work
• Strong system-level thinking across electrical, mechanical, and software domains

Project & Change Management:

• Experience executing engineering changes in production environments
• Ability to manage multiple priorities while maintaining documentation and configuration discipline

Education and Experience

• Master’s degree in Electrical Engineering, Controls Engineering, or a related field
• 5 years of experience in controls and electrical design, with experience in PCB development, or a PhD in place of
• experience
• Prior experience overseeing or working with outsourced design teams is preferred
• Familiarity with integrated electromechanical systems and embedded control environments