Job Overview

The Senior Injection Molding Process Engineer is responsible for leading the development, optimization, and sustainment of injection molding processes to ensure world class safety, quality, delivery, and cost performance. This role serves as a technical authority for molding operations, providing advanced troubleshooting, mentoring junior engineers and technicians, and driving continuous improvement through scientific molding principles, data analytics, and cross functional collaboration.

Job Requirements

Technical & Process Leadership

•    Lead the development, validation, and optimization of injection molding processes using scientific molding methodologies (cavity pressure analysis, process windows).
•    Establish and maintain robust, capable, and repeatable molding processes that meet or exceed quality, safety, and efficiency requirements.
•    Serve as the technical escalation point for complex molding issues (e.g., short shots, flash, warp, sinks, burns, dimensional instability).
•    Define and approve mold and press setup standards, processing documentation, and control plans.

Tooling, Materials & Equipment

•    Partner with tooling engineers and mold builders to define  requirements, gate and runner design, venting, cooling, steel selection, and wear surfaces.
•    Specify and optimize resins, regrind strategies, additives, and colorants based on performance, cost, and regulatory requirements.
•    Lead commissioning and qualification of new molds, auxiliary equipment, and molding machines (electric presses).
•    Drive preventative maintenance strategies for molds and processing equipment to improve uptime and longevity.

New Product Introduction (NPI)

•    Lead molding activities during new tool launches, including process development.
•    Collaborate cross functionally with Product Engineering, Quality, Maintenance, Supply Chain, and Operations to ensure flawless launches.
•    Conduct risk assessments (PFMEA, control plans) and ensure mitigation actions are implemented and verified.

Continuous Improvement & Metrics

•    Drive scrap reduction, cycle time optimization, OEE improvement, and cost of conversion reduction initiatives.
•    Utilize data analytics, SPC, and process monitoring to identify trends and proactively prevent defects.
•    Champion Lean, Six Sigma, and structured problem solving methodologies (A3, 8D, DMAIC).
•    Support sustainability initiatives, including material utilization, energy efficiency, and waste reduction.

Leadership & Mentorship

•    Act as a technical mentor for process engineers, technicians, and operators.
•    Develop training content and deliver hands on coaching in scientific molding and best practices.
•    Influence without authority and effectively communicate complex technical information to leadership and stakeholders 

What your background should look like

  •     7–10+ years of progressive experience in injection molding process engineering
•    Proven experience leading complex troubleshooting and high volume manufacturing operations.
•    Core Technical Skills (Senior Level)
•    Expert knowledge of scientific molding principles and process characterization.
 •   Advanced understanding of: 
 •   Polymer behavior (amorphous vs. semi crystalline)
 •   Rheology, shear, cooling, and crystallization
 •   Mold filling, packing, and cooling dynamics
•    Proficiency with process monitoring tools (cavity pressure, temperature sensing, SPC systems).
•    Strong capability in DOE and statistical analysis for process optimization and root cause analysis.
•    Experience with multi cavity, hot runner, family tools, and high precision/critical tolerance molding.
•    Familiarity with automation, robotics, vision systems, and downstream assembly processes.

 Systems & Compliance

•    Working knowledge of quality systems (ISO 9001, IATF 16949, ISO 13485, or equivalent).
•    Experience supporting PPAP, validation protocols, and audit readiness.
•    Ability to create and maintain technical documentation, work instructions, and standard operating procedures.

Preferred Qualifications

•    Bachelors  degree in Engineering or Plastics Engineering.
•    Industry certifications (e.g., RJG Master Molder, Paulson, Six Sigma Green/Black Belt).
•    Experience with regulated industries (medical, automotive, aerospace).
•    Exposure to global manufacturing environments and supplier development

Competencies