Senior Staff Consultant (Metallurgy)

Posted 2 Days Ago
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Kansas City, MO, USA
In-Office
Senior level
Consulting • Design
The Role
Conduct forensic metallurgical failure analyses for industrial, insurance, and litigation matters. Perform materials testing and microscopy, direct laboratory staff, prepare technical reports, advise clients and project teams, coordinate project schedules and budgets, and potentially testify as an expert witness. The role involves office and field work in industrial, construction, and damaged-structure environments, with travel as required.
Summary Generated by Built In

About ESi 

Engineering Systems Inc. (ESi) is an engineering and scientific investigation and failure analysis firm. We are frequently retained by law firms, insurance companies, and manufacturers to answer complex technical questions on projects ranging from small, focused investigations to large-scale, high-profile losses.

Our work spans a wide range of challenges, including major transportation accidents, equipment and product failures, personal injury claims, and damage to residential, commercial, and industrial structures. The variety, complexity, and real-world impact of our projects create deeply fulfilling and intellectually engaging careers for our consultants.

At ESi, you’ll have the opportunity to shape your own path while being supported by a collaborative culture, national expertise, and industry-leading resources.

Why ESi

ESi’s Materials Practice focuses on hands-on failure analysis and advanced materials characterization across industries. With access to a network of in-house laboratories, engineers evaluate material behavior and performance in a collaborative environment that emphasizes technical rigor and continuous development.

Key Responsibilities

  • Perform forensic, root cause failure analysis in industrial, insurance, and/or litigation projects as part of a team environment
  • Write technical reports, communicate effectively with clients, perform research and present technical material clearly and concisely to clients and internal colleagues
  • Ability to review and understand technical literature and reports
  • Perform both traditional and case-specific testing and/or analysis
  • Confer with project staff to outline work plan and to assign duties, responsibilities, and scope of work
  • Coordinate activities of project personnel to ensure project progresses on schedule and within prescribed budget 
  • Potential to testify in deposition or trial in litigation matters as an expert witness
  • Confer with project personnel to provide technical advice and to resolve problems 
  • Travel as required for project work and business and professional development events

 Qualifications

Education / Certifications / Licenses Required 

  • Bachelors in Metallurgical Engineering, Materials Engineering, and/or Materials Science or related field is required
  • Master’s or Ph.D. in Metallurgical Engineering, Materials Engineering, and/or Materials Science or related field is preferred
  • Professional Engineer (P.E.) license preferred, or willingness to obtain
  • CWI, CQE, API certifications are a plus

Experience Required

  • 5-10 years of experience in materials/metallurgical research, forensic consulting, materials/metallurgical engineering, or a related field
  • Experience and familiarity with metallurgical/materials laboratory procedures and testing and capable of directing staff in performing high-quality lab work
  • Experience in materials failure analysis with a focus on metallurgy, materials science, and mechanics of materials 
  • Knowledge of fractography and metallography techniques
  • Experience in utilizing a scanning electron microscopy (SEM) with X-ray energy dispersive spectroscopic (EDS) analysis capability in addition to the ability to direct staff in performing 
  • Experience and/or knowledge of analytical techniques and laboratory equipment related to failure of metals and alloys, including optical microscopy, metallography, and sample preparation
  • Experience or exposure to insurance claims and/or product liability matters preferred
  • Ability to conduct litigation consultation and interact with attorneys, adjusters, and paralegals
  • Deposition and trial experience as an expert witness, or a willingness to become a testifying subject matter expert
  • Excellent technical and critical thinking skills

Other Technical & Non-Technical Skills 

  • Excellent written and oral communication skills and ability to effectively communicate complex technical topics and findings to a wide variety of audiences
  • A team player actively engaging others in accomplishing project work and office goals both within their home office as well as across offices and other technical disciplines throughout ESi
  • Basic understanding of other technical and engineering disciplines for effective collaboration and partnership on multidisciplinary teams
  • Ability and desire to market ESi and grow the materials failure analysis specialty
  • Ability and desire for career advancement 

What We Can Offer You

We believe great work happens when people feel supported, challenged, and trusted. Some of the benefits we offer include:

  • Medical, Dental & Vision
  • Life Insurance/Voluntary Life Insurance/Universal Life Insurance
  • 401k with employer match
  • Flexible Time Off (FTO) – encouraged to take 20 days of paid time off/year 
  • 10 paid holidays (9 standard holidays and 1 floating holiday)
  • Work/Life Balance in a collaborative working environment
  • Wellness Reimbursement
  • Career growth & continuing education opportunities
  • Pet Insurance

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.

Physical Demands:

This role requires frequently sitting or standing for extended periods of time and occasionally lifting and/or moving items weighing up to 50 pounds, with infrequent lifting up to 75 pounds. The work regularly requires bending, twisting, kneeling, crouching, and maintaining balance. This position frequently requires handling and operating specialized tools and equipment and working in a variety of physical positions, including occasionally accessing tight or confined spaces.

The physical demands described here are representative of those that must be met to successfully perform the essential functions of this position. Reasonable accommodations may be made to enable individuals with disabilities to perform these essential functions.

Work Environment:

Work is performed in both office and field environments, including active construction sites, industrial settings, and damaged or compromised structures. The work environment may include exposure to varying noise levels, weather conditions, uneven terrain, and site-specific hazards. Use of personal protective equipment (PPE) may be required depending on site conditions.

The work environment characteristics described here are representative of those an employee may encounter while performing the essential functions of this position. Reasonable accommodations may be made to enable individuals with disabilities to perform these essential functions.

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.

ESi is an equal opportunity employer committed to attracting and retaining the most qualified individuals based on merit, experience, and skills. Employment decisions are made without regard to race, ethnicity, color, religion, national origin, sex, sexual orientation, age, disability, or veteran status. In accordance with applicable laws, ESi actively supports the employment of veterans and individuals with disabilities.

Skills Required

  • Bachelor’s degree in Metallurgical Engineering, Materials Engineering, Materials Science, or a related field
  • 5–10 years of experience in materials or metallurgical research, forensic consulting, materials/metallurgical engineering, or a related field
  • Experience with metallurgical and materials laboratory procedures and testing
  • Experience in materials failure analysis, metallurgy, materials science, and mechanics of materials
  • Knowledge of fractography and metallography techniques
  • Experience using scanning electron microscopy with energy-dispersive X-ray spectroscopy analysis
  • Experience with optical microscopy, metallography, sample preparation, and analytical laboratory equipment for metals and alloys
  • Ability to direct staff performing laboratory work
  • Ability to conduct litigation consultation and interact with attorneys, adjusters, and paralegals
  • Excellent technical, critical-thinking, written, and oral communication skills
  • Master’s or Ph.D. in Metallurgical Engineering, Materials Engineering, Materials Science, or a related field
  • Professional Engineer license or willingness to obtain one
  • CWI, CQE, or API certification
  • Experience with insurance claims or product liability matters
  • Deposition and trial experience as an expert witness
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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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