Senior Manufacturing Engineer

Micro Aire Surgical Instruments LLCAs a part of the global industrial organization Marmon Holdings—which is backed by Berkshire Hathaway—you’ll be doing things that matter, leading at every level, and winning a better way. We’re committed to making a positive impact on the world, providing you with diverse learning and working opportunities, and fostering a culture where everyone’s empowered to be their best.

Micro Aire, who we are:

Micro Aire Surgical Instruments, (Charlottesville, VA) is a wholly-owned subsidiary and one of five companies within the Medical Group of Marmon Holdings, a Berkshire Hathaway company. Micro Aire is a mid-sized medical device solutions company with a 45-year legacy of quality and innovation. With well-recognized brands, the company is uniquely positioned as a leader in specialty markets, including minimally invasive medical devices and equipment for aesthetics/reconstruction, endoscopic soft tissue release, and orthopedic accessories.

Micro Aire designs, manufactures, and markets cutting-edge medical devices that empower surgeons to push the boundaries of surgical precision, delivering safe, efficient, and high-quality patient outcomes.

Position Summary The Senior Manufacturing Engineer provides technical leadership for manufacturing operations supporting both existing products and new product introductions, with a strong emphasis on plastic injection molding processes, tooling, automation, and process optimization.

This role is responsible for developing, validating, optimizing, and sustaining molding processes and manufacturing systems that improve product quality, scalability, and operational performance. You’ll collaborate cross-functionally, solve complex challenges, and help shape future manufacturing capabilities through innovation, scientific molding, and continuous improvement.

What You’ll DoLead Design for Manufacturing (DFM) and Design for Assembly (DFA) efforts focused on injection molded components, improving manufacturability, quality, and cost Develop, validate, and optimize injection molding processes, tooling, fixtures, automation systems, and secondary operations

Establish and refine molding parameters (fill, pack, hold, cooling, resin drying, cycle time) using scientific molding principles

Support mold design reviews, tooling qualification, first article inspection, and production readiness

Troubleshoot molding defects such as flash, sink, short shots, warp, splay, burns, and dimensional variation

Partner with tooling vendors, resin suppliers, and automation integrators to improve mold performance and uptime

Evaluate and implement advanced manufacturing technologies including robotics, vision systems, and smart manufacturing solutions

Lead new product introduction (NPI), process validation (IQ/OQ/PQ), DOE studies, and production launch readiness

Develop scalable manufacturing strategies that support growth, efficiency, and long-term performance

Author and maintain key documentation including PFMEA, control plans, work instructions, and process flows

Lead engineering changes including tolerance analysis, resin evaluation, and mold/process improvements

Serve as technical lead for complex manufacturing and quality challenges, driving root cause analysis and corrective actions

Drive continuous improvement using Lean, Six Sigma, Kaizen, and scientific molding methodologies

Mentor Manufacturing Engineers and Process Technicians, supporting technical growth and capability development

Partner cross-functionally with Engineering, Operations, Quality, Supply Chain, and external stakeholders to achieve business objectives

What You Bring

Required:

Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Plastics Engineering, or related field5+ years of manufacturing engineering experience, ideally supporting injection molding or high-volume production environments

Hands-on experience with injection molding process development, scientific molding, tooling validation, and troubleshooting

Preferred:

Experience with automation, robotics, vision systems, or advanced manufacturing technologies

Knowledge of engineered thermoplastics, resin…