Design for Manufacturing, Expert Engineer - Operations Engineering

Novocure is a global publicly-traded commercial-stage oncology company developing a profoundly different cancer treatment therapy called Tumor Treating Fields (TTFields) for patients with solid tumors. TTFields therapy is a non-invasive, novel, antimitotic treatment modality which utilizes proprietary technology attempting to slow or reverse tumor progression by inducing tumor cell death. Novocure's commercialized product, Optune, is approved for the treatment of adult patients with glioblastoma (GBM) in the USA, Europe and Israel. Novocure has ongoing or completed clinical trials and is further expanding its efforts into several other solid tumor indications - non-small cell lung cancer, pancreatic cancer and other types of solid cancers.

Currently we are looking for a Design for Manufacturing (DFM) Expert Engineer to join our office in Cracow, Poland. 

This is a full-time, exempt position located in our Krakow Poland office and reports to the Senior Manager, Manufacturing Process Engineering. The role is hybrid and requires physical presence at the office 3 times per week. 

Job Summary

The Design for Manufacturing (DFM) Expert Engineer designs and optimizes manufacturing processes to enhance reliability, reduce cost, and ensure compliance while reflecting design intent. The role partners with Design Engineering, Operations Engineering, Quality, Supply Chain, Sustaining Engineering, and Production sites from concept through prototyping to full-scale production. The DFM Expert drives implementation within the supply chain with a focus on high quality, cost, and scalable mass production volumes.

Essential Duties and Responsibilities

• Interface with Design Engineering to review product designs for manufacturing feasibility and translate assembly strategy into actionable design changes.
• Provide detailed Design for Manufacturability (DFM) reviews of product, process, and tooling designs; develop dimensional control strategies.
• Plan and execute virtual/practical builds to review assembly process requirements; drive PFMEAs, control plans, and process documentation.
• Participates in lean manufacturing and error-proofing strategies; supports processes validation and tools qualifications.
• Quantify cost/benefit of design alternatives early in the program; communicate data-driven recommendations to project teams.
• Assess outsourced manufacturing capabilities with Manufacturing Process Engineering and implement new processes/equipment as justified.
• Champion Six Sigma, Lean, 5S, and Kaizen to reduce cost and time-to-market and to increase quality and throughput.
• Collaborate across engineering disciplines to generate and implement design and process changes; maintain PFMEAs with Design and Quality.
• Act as Process Engineer and support peers during supplier visits and process-related activities.

Soft-Goods Manufacturing – Focused Responsibilities (Preferred Expertise)

• Support the development and optimization of soft-goods processes including cutting, kiss-cutting, slitting, lamination, bonding, and assembly of flexible stacks used in Novocure wearable arrays.
• Supports the definition of requirements and handling methods for hydrogels (e.g., hydration window, tack, thickness), medical-grade foams (density/ILD), polymer films (e.g., PU, PET), conductive textiles (surface resistivity), and adhesive laminates (peel, shear, tack).
• Supports suppliers in cutting selections, such as rotary/flatbed die cutting, laser cutting (CO₂/fiber), ultrasonic or thermal bonding, pressure/heat lamination, and roll-to-roll manufacturing.
• Partner with converters and material suppliers on DFx, material selection, qualification, and change control.
• Supports pilot builds and DOEs to set robust process windows; implement mistake-proofing (poka‑yoke) for orientation, placement, and layer sequencing of flexible laminates.

Electronics Manufacturing – Focused Responsibilities (Preferred Expertise)

• Supports the development and optimization of manufacturing processes for electronic assemblies including PCB, SMT, and flex‑circuit‑based subsystems used in Novocure therapeutic devices.
• Review electronic designs for manufacturability (DFM) with focus on solderability, component spacing, thermal relief, panelization, handling, and automated assembly constraints.
• Supports process validation requirements for SMT reflow, selective soldering, conformal coating, electronic potting/encapsulation, and electrical test processes (ICT, FCT).
• Supports best practices for flexible‑circuit handling, including bend‑radius controls, strain‑relief strategies, reinforcement materials, adhesive layer sequencing, and robust stack‑up definition.
• Collaborate with PCB and flex‑circuit suppliers on impedance control, layer stack-up design, trace geometries, dielectric selection, laser‑drilled microvias, tolerance analysis, and manufacturability improvements.
• Supports supplier qualification and audits for PCB, flex‑circuit, and electronic assembly vendors; drive corrective actions, yield improvement, and process cost reductions.
• Integrate electronics and soft‑goods considerations by defining interactions between flex circuits, adhesive stacks, hydrogels, foams, and other materials in Novocure wearable systems.

Qualifications / Knowledge

• Bachelor’s degree in electrical, mechanical, biomedical engineering or a related field.
• Proven experience in manufacturing within medical devices or similarly regulated sectors.
• Strong understanding of Lean and Six Sigma methodologies; certification is a plus (e.g., Green/Black Belt).
• Working knowledge of statistics and data analysis (e.g., DOE, SPC, capability, GR&R).
• Familiarity with PCB fabrication/assembly and IPC acceptability criteria is highly desirable.
• Working knowledge of FDA Quality System Regulations and relevant standards (e.g., 21 CFR 820, ISO 13485, EU MDR).
• Excellent communication skills to collaborate cross-functionally and present technical decisions clearly to varied audiences.
• Ability to prioritize and manage multiple projects; comfortable working both independently and in teams under tight timelines.

Soft-Goods Experience – Preferred Expertise

• Hands-on experience with soft-goods manufacturing for wearable/skin-contact medical devices, including hydrogels, medical foams, polymer films, conductive textiles, flexible electrodes, and adhesive laminates.
• Process engineering for die cutting, laser cutting, kiss-cutting, slitting, pick-and-place of flexible layers, ultrasonic/thermal bonding, lamination (island placement, multi-layer stacks), and roll-to-roll operations.
• Knowledge of relevant equipment: rotary/flatbed die cutters, laser systems, ultrasonic welders, thermal bonders/laminators, vision alignment systems, environmental chambers, and precision converting tools.

Electronics & Flexible Circuit DFM – Preferred Expertise

• Experience in DFM within the electronics industry, including PCB, SMT, and electronic subsystem manufacturability assessments.
• Preferred experience with flexible circuits such as polyimide flex‑PCBs, printed conductive‑ink circuits, and flexible interconnects.
• Understanding of bend‑radius constraints, strain‑relief features, adhesive stack-ups, and DFM constraints for flex assemblies.
• Experience collaborating with flex‑circuit vendors on impedance control, trace geometry, microvias, and panelization for volume production.

Other

• Ability to travel to manufacturing sites domestically and internationally as required.
• Exceptional organization, flexibility, and patient-oriented mindset; strong problem-solving and attention to detail.
• Fluent English, spoken and written (C1 level minimum).

COMPENSATION:

The annual base salary ranges from 215,000 – 258,000 PLN gross yearly*.

This pay range is the range of base pay compensation within which Novocure expects to pay for this role at the time of this posting. Individual compensation within this range depends on a variety of factors, including, but not limited to, prior education and experience, job-related knowledge and skills demonstrated.

BENEFITS:

• Performance related bonus
• Life Insurance
• Multisport card/Benefit system
• Private Medical care
• ..and more!

We are looking forward to receive your application to Karolina Zwolak-Grzybek, Senior Talent Acquisition Partner through our Applicant Portal. Please find more information about Novocure and our therapy on our website www.novocure.com