Nikolai Semenov

Belgrade, Serbia · Full-time and co-founder

Applied R&D — biobased and fiber-filled polymer composites for food-contact packaging

Led applied R&D and product development for biobased and fiber-filled polymer composites for rigid food-contact packaging, covering formulation development, materials characterization, compounding, processing, pilot production, and customer validation. Built the R&D function and laboratory from the ground up, combining polymer science and rheology with hands-on process development and industrial scale-up.

• Built the R&D function from inception — established the laboratory, specified and procured equipment, developed experimental workflows and analytical methods, and built the technical infrastructure required to move from laboratory development to pilot manufacturing.
• Built and led a multidisciplinary R&D team — recruited and managed a team of researchers and engineers working across formulation development, materials characterization, testing, and process development.
• Developed and optimized biobased and fiber-filled formulations for rigid food-contact packaging, working from raw-material selection and formulation design through compounding, processing, and pilot validation.
• Developed bark-based polymer composites and optimized the interaction between biodegradable polymer matrices, natural fillers, plasticizers, and processing additives to achieve the required balance of mechanical performance, moisture management, and processability.
• Extended fresh berry shelf life by 7 days and mushroom shelf life by 4 days through material and packaging optimization, supporting customer validation and commercialization .
• Developed and optimized processing routes for natural-filler composites, including raw-material preparation, twin-screw compounding, pelletizing, injection molding, and thermoforming. Extrusion and compounding , injection molding and thermoforming .
• Investigated structure–property and processing–property relationships in moisture-sensitive and highly filled polymer systems, using rheology and materials characterization to identify causes of processing instability and guide formulation decisions.
• Optimized processing conditions for challenging formulations, including feeding, screw configuration, temperature profiles, degassing, throughput, and molding parameters, to establish stable processing windows for pilot production.
• Supported equipment selection, commissioning, and modification, including polymer-processing and laboratory equipment, and translated laboratory findings into practical production procedures.
• Performed manufacturability pre-screening of part geometry using Altair Inspire Mold to assess draft angles, venting requirements, and potential air traps before transferring tooling requirements to mold designers.
• Prepared material specifications, validation protocols, and technical documentation for food-contact packaging development, working with the requirements of EU food-contact legislation including Regulation (EU) No 10/2011 and Regulation (EC) No 1935/2004, as well as the emerging requirements of the Packaging and Packaging Waste Regulation (PPWR).
• Worked across the full development cycle, from raw-material screening and laboratory experiments to pilot batches, customer trials, and preparation for industrial production.

Moscow, Russia

15-year engineering career across polymer materials, rheology, composite development, and industrial technology transfer

Developed polymer formulations, filled composites, elastomers, and functional materials across a broad range of industrial and research applications. Led experimental programs from material design and laboratory characterization through process development, prototype production, and technology transfer, working with both academic teams and industrial partners. Combined polymer physics, rheology, materials characterization, and hands-on processing to identify root causes of material and manufacturing problems and translate them into practical engineering solutions.

• Smart Materials Engineering — developed electro- and magnetorheological suspensions and elastomeric materials for field-responsive applications, including semi-active vibration-control systems. Led experimental work and coordinated development activities across research groups through to working prototypes.
• Polymer & Composite Formulation: Developed reinforced rubber, elastomeric, and polymer composite formulations, optimizing filler–matrix interactions and modifying natural and mineral fillers to achieve targeted mechanical and processing properties. Developed an organosilane-based surface-modification process for mineral fillers, including in-situ modification during milling.
• Rheology & Process Diagnostics: Used rheological analysis, microscopy, and materials characterization to investigate structure–property and processing–property relationships in complex polymer systems, diagnose formulation and processing failures, and identify root causes of quality defects.
• Industrial Silicone & Elastomer Engineering: Developed and scaled silicone formulations for electrical insulation applications and prepared production-oriented process documentation. Developed fiber-reinforced polymers and specialized elastomeric damping materials for demanding operating conditions, including torsional dampers for overhead high-voltage power lines.
• Failure Analysis & Materials Diagnostics: Applied AFM, interferometric surface analysis, and other characterization techniques to investigate filler–matrix interactions, surface morphology, and material failure mechanisms, including analysis of impact-damaged protective materials.
• Functional & Biomedical Materials: Engineered core-shell magnetically responsive sorbent materials for selective target extraction and developed analytical workflows for bio-fluid processing and fractionation.
• Nanocomposite Materials: Developed and characterized elastomeric composites containing low concentrations of carbon nanotubes, using probe microscopy and mechanical testing to assess reinforcement and dispersion.
• Technical Leadership — supervised MSc students, mentored junior researchers, and coordinated experimental work across multidisciplinary projects. Mentored early-career researchers through applied research projects and technology-development programs.
• Contributed to joint academic–industrial R&D programs, taking projects from experimental concept and laboratory validation through prototype development, process optimization, and technology transfer to industrial partners.
• Authored and co-authored scientific and technical publications covering polymer rheology, composite materials, functional polymer systems, and materials engineering.

Moscow, Russia · Part-time, ~20% FTE

Sustainable packaging startup — biobased and biodegradable polymer composites

Co-founded and led applied R&D for an early-stage sustainable packaging venture focused on developing biobased polymer composites for disposable products. Worked across material formulation, compounding, processing, prototype development, and pilot manufacturing, translating laboratory concepts into manufacturable products.

• Co-founded the venture and directed applied R&D — developed biobased polymer composite formulations for disposable products, including injection-molded cups and tableware.
• Investigated degradation and environmental stability of plant-based polymer systems under controlled laboratory and real-use conditions, evaluating material performance and degradation behavior.
• Developed the first product prototypes and MVP and transferred the developed materials to pilot manufacturing to evaluate processability, product quality, and manufacturing stability.
• Formulated and optimized materials for compounding and injection molding, addressing filler dispersion, processability, and consistency of the finished products.
• Performed mold-filling simulations using SolidWorks Plastics to evaluate flow behavior, weld-line formation, and potential air traps, and used the results to support tooling specifications and mold design.
• The startup was selected to be showcased at Expo 2020 as part of the Russian national pavilion.

Worldwide · Remote, ~5% FTE · Self-employed

Provided technical consulting to polymer and composite manufacturers, supporting formulation development, polymer processing, equipment commissioning, troubleshooting, and production stabilization. Worked across wood–polymer composites, recycled PVC, elastomers, and silicone systems, combining materials science with practical process engineering.

• Advised manufacturers on polymer compounding, extrusion, and injection molding, diagnosing formulation and processing issues responsible for unstable production and inconsistent product quality.
• Commissioned and stabilized an industrial compounding line — supporting equipment start-up, process setup, formulation adjustment, troubleshooting, and transition to stable production.
• Developed and optimized custom polymer formulations for different processing technologies and product requirements, including wood–plastic composites , recycled PVC, elastomers, and silicone-based materials.
• Developed flame-retardant polymer formulations using ATH and Mg(OH)₂-based systems, optimizing filler loading and processing conditions to achieve the required fire-performance characteristics and support product certification. Fire-retardant systems
• Implemented quality-control procedures and raw-material qualification workflows to improve consistency and establish repeatable production standards.
• Supported clients with technical documentation, process troubleshooting, and practical recommendations for improving the reliability of polymer-processing operations.