Orthotic Builder - Vacuum Form

Orthotic Builder 2 - Vacuum Form

Position Type Full Time

Responsible for performing vacuum forming processes for orthotic components including shells, carbon fiber, and poly-pro materials. Ensures all products are formed, trimmed, and processed according to company specifications, quality standards, and production requirements.

Key Responsibilities

• Verify accuracy of orders by matching  wood positive with order documentation.
• Organize and group orders for efficient workflow within the vacuum forming area.
• Operate ovens and vacuum forming equipment to heat and form orthotic shells.
• Monitor material heating (e.g., shells, carbon fiber, poly-pro) and ensure proper forming temperatures and times are achieved.
• Place heated materials onto wood positive, molds, or library forms and operate vacuum chamber to shape components.
• Apply hands-on techniques during vacuum forming to prevent defects such as wrinkles or improper shaping.
• Perform vacuum forming for various materials including:
  • Standard shells
  • Carbon fiber (semi-rigid and rigid)
  • Poly-pro materials in specified thicknesses
• Utilize metal molds or wood positives where specified by order instructions.
• Place orders with documentation In tote and transfer to the next production stage.
• Maintain the 6S workplace organization standards within the assigned area on a daily basis.
• Ensure all work performed meets company standards for quality.
• Support and operate in a lean manufacturing one piece flow environment.
• Perform additional laboratory duties as assigned by the Lab Manager

Key Competencies & Required Experience

• High school diploma or equivalent
• Ability to stand for up to 8 or more hours per day while performing the functions of the job
• Ability to read and interpret work orders, specifications, and special instructions
• Hand-eye coordination
• Regard for safety.
• Ability to work well in a team-oriented, production-focused environment.
• Ability to learn and retain new information.
• Strong attention to detail and accuracy.
• Ability to follow processes and escalate issues appropriately.
• Willingness to learn and adapt in an evolving environment.

Work Location & Schedule

• Primary location:
  Roanoke, Va.
• Regular hours:
  Monday through Friday, 7:00 a.m. to 3:30 p.m.
• Flexibility to adjust schedule as needed to support business operations.

Work Environment

• Manufacturing floor environment with heated ovens and materials and vacuum forming equipment.
• Exposure to noise, dust, and production materials
• Use of required personal protective equipment (PPE)
• Moderate to high noise level consistent with manufacturing operations

Communication Requirements

• Ability to clearly communicate operational issues to team members and supervisors.
• Strong interpersonal skills and team collaboration
• Ability to document basic production or downtime information.
• Regular interaction with operations, maintenance, and engineering teams

Physical Demands

• Frequent standing, walking, and movement throughout the production area
• Regular bending, reaching above shoulder height, and handling of materials, tools and controls.
• Ability to lift up to 20 lbs. as needed.
• Hands-on interaction with machinery and equipment

Ability to safely operate machinery and tools