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 designsDefine and enforce controls and electrical design standards, documentation practices, and review criteriaProvide technical leadership and mentorship to internal engineers and outsourced engineering partnersAct as a key technical decision-maker across electrical, embedded, and mechanical system boundaries2. Hands-On Controls & Electrical Design:Personally perform hands-on engineering work as required, including:Control system architecture and I/O definitionWiring diagrams, schematics, and control panel layoutsPCB schematic updates and design changesExecute design updates to support:ECOs, cost-down initiatives, supplier changes, and field issuesLeverage outsourced engineering resources when workload exceeds internal capacity or critical timelines,while retaining full technical ownership and approval responsibility3. Technical Package & Configuration Management:Own and maintain complete controls and electrical technical packages, including:Schematics, wiring diagrams, and panel layoutsPCB schematics, layouts, and BOMsI/O maps, safety circuits, and interlock definitionsLead and execute engineering change orders (ECOs), including:Technical impact analysisDocumentation updates and revision controlCross-functional coordination with manufacturing, quality, and supply chainEnsure strict configuration discipline across released and in-production electrical and controls designs4. Quality, Safety, & Reliability Responsibilities:Own controls- and electrical-related quality responsibilities, including:Verification and validation planning for control systems and PCBsDefinition of acceptance criteria and test coverageEnsure compliance with applicable electrical safety, regulatory, and industry standards (e.g., UL, CE, SGS)Partner with Manufacturing and Operations to:Identify quality escape risksSupport root cause analysis (RCA) and corrective actions (CAPA)Design systems with consideration for:Reliability, serviceability, and real-world operating conditionsSafety, integrity, and fault detectionHelp establish scalable controls and quality practices with the intent to transition ownership when a dedicated Quality Engineer is added5. Product Development, Cost Reduction, & Manufacturing Support:Drive the development and continuous improvement of control systems and electrical designs acrossproductsLead cost-reduction initiatives through:Component standardization and reuseBOM optimization and alternate sourcingDesign simplification and panel consolidationProvide direct engineering support for:System integrationElectrical troubleshooting during production and validationField issue resolution as needed6. Product Development, Cost Reduction, & Manufacturing Support:Act as the primary controls and electrical liaison between internal teams and outsourced engineeringpartnersCollaborate closely with mechanical, software, embedded, and manufacturing teams to ensuresystem-level integrationCommunicate design decisions, risks, and trade-offs clearly to the Director of EngineeringMaintain clear documentation of design intent, decisions, and changes to ensure long-term productcontinuityPerformance MetricsAccuracy, completeness, and timeliness of released controls and electrical documentationEffectiveness of ECO execution and configuration controlReduction in electrical and controls-related manufacturing or field issuesProgress against cost-reduction and reliability improvement goalsQuality and responsiveness of outsourced engineering deliverablesSkills and QualificationsTechnical Expertise:Deep knowledge of industrial control systems, motor drives, and safety circuitryStrong hands-on experience with electrical schematics, wiring diagrams, and control panel designExperience reviewing and updating PCB schematics, layouts, and BOMsFamiliarity with applicable regulatory and safety standards (UL, CE, SGS, RoHS, REACHLeadership and Collaboration:Ability to lead through technical authority and ownershipExperience directing and reviewing outsourced engineering workStrong system-level thinking across electrical, mechanical, and software domainsProject & Change Management:Experience executing engineering changes in production environmentsAbility to manage multiple priorities while maintaining documentation and configuration disciplineEducation and ExperienceMaster’s degree in Electrical Engineering, Controls Engineering, or a related field5+ years of experience in controls and electrical design, with experience in PCB development, or a PhD in place ofexperiencePrior experience overseeing or working with outsourced design teams is preferredFamiliarity with integrated electromechanical systems and embedded control environments