Molding and Tooling Engineer

At Sonos we want to create the ultimate listening experience for our customers and know that it starts by listening to each other. As part of the Sonos team, you'll collaborate with people of all styles, skill sets, and backgrounds to realize our vision while fostering a community where everyone feels included and empowered to do the best work of their lives.

This role is a hybrid position

This position is considered hybrid, allowing for a combination of remote work and in-office collaboration. Qualified applicants must live within commuting distance of our Boston, MA or Santa Barbara, CA office locations and should expect to be in office approximately 1-3 days per week. We will also consider remote based for a very qualified candidate that will come into the office once every 1-2 months for a week.

As the Molding and Tooling Engineer you will be responsible for delivery and validation of lead molding processing development and fabrication tooling designs for new product developments and secondary operations. You will work with Mechanical Engineers, Supply Chain Management and Supply Quality Engineers to identify supply base vendors, fabrication technologies and create tooling designs to deliver high volume, high value consumer products with demanding cosmetic requirements.

Using your extensive experience, you will investigate and implement industry best practices in molding process, tool design, construction and validation across a range of material and process requirements including plastic molding, metal part fabrication and decorative processes. You will directly manage the tool design, development and qualification of molding and tooling designs required to deliver new product designs and support manufacturing capacity.

• Recommend material choices to meet mechanical, CMF (Color/Materials/Finish), Industrial Design and Operations requirements. Collaborate with Product Design, Industrial Design, and Mechanical Process Engineering teams to support product development.
• Experience with setting up, running and troubleshooting injection molding machines preferred.
• Ability to establish injection molding process window and cycle times.
• Provide feedback to all teams on part and manufacturing concerns with design requirements.
• Drive analytical modeling and analysis of tooling concepts and design through use of Plastic Flow simulation tools to provide upfront design feedback (Moldflow or MoldEx3D).
• Create DFM (Design for Manufacturing) documents that include gating, parting lines, ejection locations, actions, thin steel conditions, design considerations to be provided to Mechanical engineers and suppliers.
• Work directly with Quality organization to provide feedback on dimensional information, FAI, Cp and Cpk.
• Visit suppliers for onsite tool and part processing reviews, audit suppliers for plastic and metal parts and evaluate their capabilities, explore new manufacturing processes and materials and help standardize tooling practices and process controls across SONOS supplier base.
• Manage multiple development programs at once.
• Provide feedback into program schedules and risks.
• Provide feedback to the GSM team on tool prices, lead times, production cycle times, tool cavitation and expected yields.
• Mentor and develop mechanical engineers and junior tooling engineers in the area of plastic material selection and part design.

• Bachelor’s degree in Plastics or Polymer Engineering and Mold/Tool Design, Material Science and Engineering or related field
• 6 years experience in plastics part and tool design

• Experience with engineering grade plastic resins
• Experience with tight tolerance tooling and resolving out of spec issues.
• Proficient with GD&T, SPC, DOE and Six Sigma techniques
• Experience in plastic molding, metal casting, metal extrusion and metal stamping.
• Knowledge of plastic processes of 2-shot molding, IMD, IML, and insert molding.
• Knowledge of secondary processes such as machining and decorating (anodizing, plating, painting).
• Experience working with suppliers in Asia
• Experience with CAD software (Pro/Engineer or Siemens NX solid modeling)

Research shows that candidates…