Summary
Overview
Work History
Education
Skills
Certification
CAREER HIGHLIGHTS
SELECTED PATENTS
Timeline
Generic

Ajay Chadha

Portland

Summary

Global materials executive with 20+ years of end-to-end leadership in materials innovation, R&D, and sustainability strategy across the full value chain—spanning polymers, yarns, engineered textiles, and finished goods. Demonstrated success in leading high-impact initiatives for global brands in footwear, apparel, and technical textiles, with proven ability to deliver scalable, sustainable, and commercially viable material platforms. Expertise includes polymer engineering (Reliance Industries), functional yarns (Premier Fibers), technical textile systems (Edwards Lifesciences), performance/lifestyle product creation (Nike, Coach), and enterprise roadmap development (REI, Coach). Known for driving material innovation roadmaps, transforming early-stage R&D into commercial wins, and embedding a ‘Fabric First’ culture across product and sourcing teams. Patent holder with recognized contributions to medical implants and Olympic-level footwear. Adept at leading global teams, integrating PLM and digital color systems, and pioneering AI-led discovery in green chemistry.

Overview

21
21
years of professional experience
1
1
Certification

Work History

Director, Advanced Materials Innovation

REI
Seattle
01.2023 - Current
  • Lead an 11-person global team comprising materials designers, developers, trims specialists, chemical engineers, and digital color/chemical management experts—delivering strategic initiatives across gear and apparel.
  • Spearheaded the transition of REI’s entire materials palette to PFAS-free within an accelerated timeline, aligning with climate goals and establishing a commercially viable, sustainable foundation.
  • Reengineered key fabric platforms and development processes, generating $2M in annual savings and boosting platform reuse by 35% through PLM and digital integration.
  • Optimized the global vendor base and elevated mill onboarding, aligning capabilities to performance standards and significantly reducing quality testing failures.
  • Partnered with IBM on AI-driven materials discovery for green chemistry and led a 3-year roadmap influencing seasonal planning and adoption of next-gen sustainable materials.

Director, Materials Innovation & Sustainability

Coach
New York
01.2022 - 01.2023
  • Spearheaded the launch of Coachtopia, a new circular brand achieving >70% recycled content and 30% lower carbon footprint.
  • Created supplier engagement models to integrate regenerative materials and circular feedstocks.
  • Partnered with marketing and legal to define brand-safe sustainability claims and material storylines.
  • Elevated mill onboarding and supplier validation in partnership with sourcing, significantly reducing testing failures.

Senior Researcher, Materials Innovation (Explore Team)

Nike
Portland
01.2017 - 01.2022
  • Led materials development through continuous research and analysis of new materials, processes, and technologies. Collaborated with Design & Product Creation teams.
  • LeBron 17 BB Shoe (2019) – Led development of new fusible and space-dyed yarns.
  • Luna Alpha, Women’s WC Soccer Shoe (2023) – Developed durable coatings for the shoe upper.
  • Sustainability-Focused Projects:
  • Led closed-loop TPU Nexus Project for material circularity.
  • Developed coatings using Nike Grind rubber and yarns from leather scraps.
  • Created foam/rubber fillers using municipal waste feedstock.
  • Future-Facing Projects:
  • Developed foamable yarns with external partners for integrated footwear Method of Make (MoM).
  • Led bacterial cellulose-based textile upper development.

Principal Research Engineer, Textiles

Edwards Lifesciences
Irvine
01.2014 - 01.2017
  • Created implantable textile structures for prosthetic heart valves; filed multiple patents on woven, knitted, and composite systems.
  • Built the company’s first in-house textile prototyping lab (ultrasonic bonding, weaving, laser cutting).
  • Developed bioprosthetic fabrics meeting biocompatibility, durability, and surgical performance standards.

Quality & Process Control Manager

Premier Fibers
Ansonville
01.2005 - 01.2013
  • Directed PET and PA yarn development, and pilot-to-scale extrusion programs for apparel and military uses.
  • Commissioned two melt-spinning lines and commercialized five fiber platforms.
  • Advanced color control and dye uniformity systems; reduced inter-lot variability by over 20%.

Education

MS - Textiles & Advanced Structures

North Carolina State University

MBA - Marketing

Symbiosis Institute of Management
Pune, India

B.Tech - Textile Technology

Technological Institute of Textile & Sciences
India

Skills

  • Global Materials Strategy
  • Textile Innovation
  • Cost Engineering
  • Research & Development
  • Statistical Analysis
  • Team Leadership
  • PLM & Digital Libraries
  • Fabric KPI & Risk Eval
  • Testing & Standards
  • Six Sigma Black Belt
  • Circularity & Sustainability
  • Life Cycle Assessments
  • Prototype/Pilot Tests
  • Continuous Improvement
  • Innovation Commercialization

Certification

  • Six Sigma Black Belt
  • PLM Systems (Centric, Flex)
  • Adobe Illustrator
  • Datacolor Tools
  • Color Management Systems
  • Textile Testing (AATCC, ISO, ASTM)
  • GOTS
  • GRS
  • OEKO-TEX
  • Bluesign
  • Fabric Risk & Compliance
  • Supplier Audits
  • Digital Material Libraries

CAREER HIGHLIGHTS

  • Established a Textile Center of Excellence at Edwards Lifesciences, bringing in-house fabric processing technologies such as ultrasonic bonding, 3D laser cutting, sample warping, and weaving looms to accelerate product innovation and technical capability.
  • Played a foundational role as the first Director of Materials Innovation for Coachtopia—a sub-brand launched by Coach to champion circular business models. Established core materials functions, developed scalable recycled and regenerative platforms, and led commercialization for market launch. Leveraged key trend insights to lead fabric innovation, costing, and positioning strategies that supported brand identity and value-driven product development at scale.
  • Cross-industry collaboration: Served as Subject Matter Expert on staple fibers in a steering committee commissioned by the Laudes Foundation (formerly C&A Foundation, BCI Cotton) to evaluate the techno-economic feasibility of using agricultural waste as feedstock for textiles.
  • Orchestrated a 3-year enterprise materials innovation roadmap at REI, focused on climate-smart technologies, driving annual cost savings and enhancing product margin.
  • Pioneered an AI-driven green chemistry discovery program with IBM to identify next-gen material solutions and accelerate R&D-to-market timelines.
  • Strong educational background in textile materials and color science, including testing, standards, and failure analysis. (MS, Textiles – NC State College of Textiles; 10+ patents in materials and product innovations)

SELECTED PATENTS

  • Covered Prosthetic Heart Valve (US20220079750A1)
  • Delivery Cylinder for Prosthetic Implant (US1166437B2)
  • 3D Woven Footwear Structure (US11759317B2, Nike)
  • Textured Woven Fabric for Bioprostheses (ES2995222T3)
  • Super Fly Tokyo 2020: Lightweight Knitted Upper (WO 180218WO01)
  • Docking Device with 3D Woven Fabric (US62/436866)
  • Bi-Functional Cloth for THV (US62/268,363)

Timeline

Director, Advanced Materials Innovation

REI
01.2023 - Current

Director, Materials Innovation & Sustainability

Coach
01.2022 - 01.2023

Senior Researcher, Materials Innovation (Explore Team)

Nike
01.2017 - 01.2022

Principal Research Engineer, Textiles

Edwards Lifesciences
01.2014 - 01.2017

Quality & Process Control Manager

Premier Fibers
01.2005 - 01.2013

MS - Textiles & Advanced Structures

North Carolina State University

MBA - Marketing

Symbiosis Institute of Management

B.Tech - Textile Technology

Technological Institute of Textile & Sciences
Ajay Chadha