Plastics Mechanical Engineer

JOB SUMMARY

Plastics Engineer to lead the development, optimization, validation, and continuous improvement of precision injection molding processes for demanding medical, aerospace, defense, and industrial applications. This role combines scientific molding, mold design, Moldflow simulation, advanced metrology, automation, and new product introduction activities to ensure world-class quality, dimensional performance, and manufacturing excellence.

RESPONSIBILITIES

Develop and optimize injection molding processes for precision plastic components with tight-tolerance requirements. Lead process validations including IQ/OQ/PQ activities, DOE studies, and process window development. Troubleshoot molding defects and implement corrective actions using data-driven methodologies. Support new product introductions from concept through production launch.

Conduct mold design reviews and provide Design for Manufacturability (DFM) recommendations. Utilize Moldflow simulation tools to perform fill, pack, cooling, shrinkage, and warp analyses. Recommend improvements to gating, runner, cooling, venting, and ejection systems. Utilize advanced metrology systems including CMMs, optical inspection systems, and industrial CT scanners to validate part geometry and dimensional capability.

Perform root cause analysis of dimensional variation through metrology data and statistical methods. Establish SPC, MSA (Measurement Systems Analysis), Gage R&R, and capability studies (Cp/Cpk). Collaborate with tooling, automation, quality, production, and customer teams. Evaluate and implement new manufacturing technologies, software platforms, and engineering tools.

Other duties as assigned.

QUALIFICATIONS

Bachelor's degree in Plastics Engineering, Mechanical Engineering, Manufacturing Engineering, or related field. 3+ years of injection molding and mold design. Simulation Software Experience. Strong understanding of scientific molding principles and process optimization. Experience with dimensional metrology and quality systems.

Strong analytical and problem-solving abilities. Experience in medical device, aerospace, defense, or other regulated manufacturing environments. Moldflow experience including fill, cooling, pack, shrinkage, and warp analysis. Experience with mold design, DFM, and tool qualification. Hands-on experience with CMMs, optical measurement systems, and industrial CT scanners.

Knowledge of GD&T, tolerance stack-up analysis, MSA, SPC, and capability analysis. Experience with automation systems, robotics, and vision inspection technologies. Experience with high-performance polymers including PEEK, PPS, PEI, PFA, FEP, ETFE, and LCP.