Sr. CAE Application Engineer, Mold Flow

Your Job

As a Sr. Mold Flow CAE Application Engineer, your expertise in plastic molding behaviors and molding technologies will be crucial throughout Molex connector product development cycle, from design inception through mold tooling qualification. You will apply your injection molding acumen to drive product design for manufacturability (DFM), boost tool molding performances, and elevate the efficiency of molding production, while managing priorities to adhere to product development project timelines.

The Molex Mold CAE team, with members located globally and embedded within multi-functional teams, plays a vital role in the connector product development process. Our team actively contributes to every mold tooling project by working closely with product design engineers to proactively identify and resolve design-for-manufacturing issues and collaborating with mold tooling and process engineers to make simulation-driven mold tooling and processing decisions.

Our contributions are highly valued, and our team members find their work deeply fulfilling.

• Deliver expert guidance on plastic molding behaviors to enhance product manufacturability, mold performance, and molding production efficiency for cross-functional product development teams.
• Engage with Product Design Engineers and actively participate in product design review meetings to provide design for manufacturing insights and proactively address manufacturability issues for optimizing product performance and manufacturability prior to OK-to-Tool.
• Partner with mold tooling engineers to ensure optimal runner/gate/cooling designs and to craft simulation data supported mold tooling strategies.
• Collaborate with process engineers to optimize molding process parameters.
• Conduct simulation optimization studies to boost molding production operational efficiency, targeting cycle time reduction, material usage minimization, defect reduction, and PM frequency decrease.
• Function as molding simulation project lead for project originated from local design center/plant. Drive effective communication within Mold CAE global teams and with other project stakeholders to ensure smooth molding simulation project execution.
• Take initiative and proactively identify opportunities to communicate standard workflows and team new initiatives, and to share molding simulation and molding knowledge with local and global engineering and manufacturing teams.
• Document simulation methodologies, best practices, and lessons learned from projects, and contribute to their dissemination to global cross-functional teams.
• Collect and evaluate data on molding behavior and part performance for predicted versus actual comparison studies.
• Execute additional duties as directed by management.

• Bachelor's degree in Mechanical or Polymer Engineering, or equivalent fields.
• 5+ years of proven experience in creating molding simulation models for connector products and proficiently conducting Flow, Pack, Cool, and Warp analyses using molding simulation software (such as Moldex3D, Moldflow, or Sigmasoft).
• Proficiency in using CAD system (such as NX) and meshing tool (such as Hyper Mesh).
• In-depth knowledge of plastic materials and their properties, including glass fiber-filled grades.
• Expertise in interpreting simulation results, diagnosing potential issues in molding and product performance, and suggesting solutions and risk mitigations for product design, tooling, and processing.
• 10% travel requirements (domestic and international).

• Experience with structural FEA tools like Abaqus or Ansys, and integrating them with molding simulation software.
• Strong leadership skills in fostering collaboration and driving team performance.
• Hand‑on experiences with metal injection molding (MIM).
• Hand‑on experiences with thixo‑molding (magnesium injection molding).
• Familiarity with CT data analysis using Volume Graphics.
• Master's degree or PhD in Mechanical Engineering, Polymer Engineering, or equivalent fields.
• 8+ years of proven experience in creating molding simulation models for connector products and proficiently conducting Flow, Pack, Cool, and…