Senior Managing Consultant (Metallurgy)

Posted Yesterday
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11 Locations
In-Office
Senior level
Consulting • Design
The Role
Lead complex metallurgical forensic investigations, develop and defend expert opinions, provide testifying expert services, manage multidisciplinary teams and labs, grow client relationships and revenue, mentor junior staff, and support business development.
Summary Generated by Built In

Compensation will be made up of a competitive base salary as well as bonus potential determined by your own individual performance and the performance of the organization overall.


About ESi 

Engineering Systems Inc. (ESi) is a multidisciplinary engineering and scientific investigation and failure analysis firm. We primarily work with law firms, insurance companies, and manufacturers on small to large-scale projects to answer any technical questions they have. As a firm, our projects can entail investigating major transportation accidents, equipment failures, personal injury claims, and damage to structures. At ESi you will have access to:

  • State-of-the-art metallurgical laboratories and testing capabilities.
  • A multidisciplinary team of engineers and scientists across industries.
  • Established relationships with law firms, insurers, and corporate clients.
  • Infrastructure to support expert testimony, report development, and large-scale investigations.
  • A platform to grow and scale your practice within a nationally recognized firm.

The variety and depth of our project work create a broad range of fulfilling roles at ESi. This role offers meaningful opportunities to expand your technical impact, grow your client relationships, and help shape the direction of our mechanical engineering practice.

About This Role

ESi’s Metallurgy group is seeking an experienced consultant with national consulting and expert witness experience. The ideal candidate is a recognized expert in metallurgical failure analysis and root cause investigations, with a demonstrated ability to develop and sustain client relationships in litigation, insurance, and industrial sectors. 

This role is intended for an individual who combines technical excellence, testifying experience, and business development capability, with clear opportunity to broaden influence and help grow a practice area within ESi. The successful candidate will lead complex investigations, develop expert opinions, and play a key role in expanding client relationships and revenue generation.

Individuals with a track record of success in consulting and/or experience working closely with legal and insurance professionals are encouraged to apply and may be considered for opportunities and levels reflecting their experience and established expertise.

Key Responsibilities

  • Leads and manages complex forensic investigations by utilizing a multidisciplinary team
  • Serves as a testifying expert in depositions, arbitration, and trial settings.
  • Develops and defends independent expert opinions supported by sound engineering analysis.
  • Writes technical reports, communicates effectively with clients, and presents technical material clearly and concisely to clients and internal colleagues.
  • Builds and maintains a book of business, including direct client relationships with attorneys, insurers, and industry clients.
  • Reviews project proposals or plans to determine time frame, funding limitations, procedures, staffing requirements, and allocation of resources for various phases of the project.
  • Directs and coordinates the activities of project personnel to ensure projects progress on schedule and within budget.
  • Works with Business Development staff and independently identifies opportunities to expand the client base and develop new engagements.
  • Directs laboratory and field investigations, including failure analysis, testing, and materials characterization.
  • Mentors and develops junior staff, contributing to the growth of ESi’s technical capabilities.
  • Participates in strategic business development initiatives in coordination with ESi leadership.

Education Requirements

  • B.S. in Materials Science or an allied discipline from an ABET accredited university required with Twelve years of diverse consulting and industry experience; or
  • M.S. in Materials Science or an allied discipline, or equivalent, with eight years of relevant post graduate professional experience; or
  • Ph.D. in Materials Science or an allied discipline with at least six years of relevant post graduate consulting experience.

Certifications Preferred

  • Professional Engineer (PE) license preferred (or willingness to obtain)
  • CWI, CQE, and API certifications are a plus

Experience Requirements

  • 6+ years of technical litigation consulting experience, with a desire to develop a practice in metallurgy.
  • Demonstrated experience as a testifying expert in litigation, arbitration, or insurance-related matters.
  • Proven ability to originate and sustain client relationships, with a track record of revenue generation.
  • Experience working within a consulting or expert services environment, ideally supporting legal matters.
  • An existing or developing portable book of business is strongly preferred.
  • Ability and desire to grow a practice within a multidisciplinary engineering firm.
  • Excellent technical and critical thinking skills.

Skills Required

  • Willingness and ability to testify in a court of law or arbitration; prior testifying experience is a plus.
  • Excellent written and oral communication skills, with the ability to communicate complex technical topics to diverse audiences.
  • Ability to interact with clients in a professional manner and develop business internally and externally.
  • Knowledge of and operational ability with SEM and EDS equipment.
  • Experience with laboratory equipment and techniques, including stereoscopy (KEYENCE), microscopy, metallography, and sample preparation.
  • Is a team player who actively engages others in accomplishing project work and office goals across multiple offices and technical disciplines within ESi.
  • Basic understanding of other engineering and technical disciplines for effective collaboration on multidisciplinary teams.
  • Ability and desire to market ESi and contribute to the growth of the materials failure analysis specialty.
  • Demonstrated capacity for revenue generation in a consulting environment.
  • Demonstrated ability and desire for career advancement.

Computer Skills Required

  • Intermediate to advanced proficiency in Microsoft Office (Excel, Word, PowerPoint)
  • Internet research proficiency

Physical Demands

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. While performing the duties of this job, the employee is occasionally required to stand, walk, climb stairs and ladders, and sit. Site inspections may require that employees stand, walk, carry tools, and/or work from an elevated position for extended periods of time. 

Work Environment

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions. The noise level in the work environment is usually moderate. Noise levels at project sites are variable and may be loud enough to require hearing protection.

Some of the benefits we can offer you!

  • Medical, Dental & Vision
  • Life Insurance/Voluntary Life Insurance/Universal Life Insurance
  • 401k with employer match
  • Annual Bonus
  • Flexible Time Off (FTO) – encouraged to take at least 20 days of paid time off/year 
  • Pet Insurance
  • Work/Life Balance
  • 10 paid holidays (9 standard holidays and 1 floating holiday)
  • Access to OnePass – provides unlimited access to a nationwide network of gyms 
  • Wellness Reimbursement
  • Career Growth
  • Professional Development investment
  • Continuing education opportunities 

To all recruitment agencies: ESi does not accept unsolicited resumes from search firms or agencies. Any resume submitted to any employee of ESi without a prior written search agreement will be considered unsolicited and the property of ESi. Please, no phone calls or emails.

It is the policy of ESi, as an equal opportunity employer, to attract and retain the best qualified individuals available, without regard to race/ethnicity, color, religion, national origin, gender, sexual orientation, age, disability, or veteran status. ESi is committed to recruiting, hiring, and promoting people with disabilities, as well as veterans. If you need assistance with completing the electronic application, please email your request to employment @ engsys.com


Skills Required

  • B.S. in Materials Science or allied discipline from an ABET-accredited university with 12 years consulting/industry experience; or M.S. with 8 years; or Ph.D. with 6 years
  • 6+ years of technical litigation consulting experience
  • Demonstrated experience as a testifying expert in litigation, arbitration, or insurance-related matters
  • Proven ability to originate and sustain client relationships and generate revenue
  • Existing or developing portable book of business
  • Willingness and ability to testify in court or arbitration
  • Knowledge of and operational ability with SEM and EDS equipment
  • Experience with laboratory equipment and techniques including KEYENCE stereoscopy, microscopy, metallography, and sample preparation
  • Excellent written and oral communication skills, with ability to present complex technical topics clearly
  • Ability to build and maintain client relationships with attorneys, insurers, and industry clients
  • Experience directing and coordinating project personnel to meet schedules and budgets
  • Mentoring and developing junior staff
  • Intermediate to advanced proficiency in Microsoft Office (Excel, Word, PowerPoint)
  • Internet research proficiency
  • Professional Engineer (PE) license preferred or willingness to obtain
  • CWI, CQE, and API certifications are a plus
  • Ability to perform site inspections, including standing, walking, carrying tools, and working from elevated positions
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The Company
HQ: Aurora, Illinois
500 Employees

What We Do

Engineering Systems Inc. (ESi) is a forensic engineering and scientific investigation firm committed to providing actionable solutions to industry and technical challenges through data-driven insights and multidisciplinary collaboration. Our experts leverage advanced technologies and professional expertise to equip clients across the globe with comprehensive analyses, and recommendations on projects of any size or complexity.

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