Sr. Molding Engineer

Responsible for the development, optimization and sustaining robust molding processes for liquid silicone rubber (LSR) and high consistency rubber (HCR) utilizing injection, transfer and compression molding processes. The Process Engineer plays a key role in driving process capability, optimizing cycle times, reducing scrap, troubleshooting production issues and ensuring stable manufacturing performance across all molding work centers.

The Process Engineer collaborates closely with the Tooling, Production, Quality, NPI and Maintenance teams to ensure successful product launches, consistent quality and efficient manufacturing processes.

Process Development & Optimization:

• Develop, validate and optimize molding processes for:
  • HCR injection, compression and transfer molding.
• Multi-cavity, family molds and multi-shot configurations.
• Apply scientific molding techniques to establish:
  • Pack/hold strategies.
  • Cure and thermal control profiles.
  • Venting and flash prevention parameters.
• Performs process determination and DOE studies to optimize process by improving capability (Cp/Cpk) and reducing variation.
• Establish and maintain standardized process parameter sheets, recipes and work instructions.

• Provide daily technical support to address molding issues such as:
  • Flash, short shots, cure variations, knit lines and voids.
  • Sticking and ejection problems.
  • Inconsistent shrink, durometer and dimensional stability.
• Lead structured root cause analysis (5 why, 8D, fishbone) and implement robust corrective and preventative actions.
• Train operators and technicians in molding best practices and process discipline.

• Partner with Tooling Engineer on:
  • Gate/vent design for silicone and rubber molds.
  • Cold runner or valve-gate LSR systems.
  • Mold thermal management and vent maintenance.
  • Mold qualification and production readiness.
• Support maintenance to ensure equipment (presses, injection units, dosing systems, thermolators) operate within validated performance parameters.
• Provide feedback to improve mold robustness, reduce tool wear and minimize flash related issues.

• Cycle time optimization.
• Scrap and rework reduction.
• OEE (availability, performance and quality).
• Material usage and yield optimization.
• Participate in LEAN, Kaizen, 5S and efficiency projects.
• Use SPC, data analytics and process monitoring to identify and address instability.

• Work with NPI Engineering on:
  • Feasibility reviews.
  • New mold trials and qualification.
  • Launch readiness and transfer to production.
  • Support Quoting/Estimating with:
    • Cycle time projections.
    • Cavitation/tooling strategy input.
• Communicate clearly with Production and Quality teams on process changes, risks and improvement projects.

• Bachelor’s degree in an Engineering (Mechanical, Manufacturing, Materials, Plastics, Polymer)
• 5+ years’ direct experience in silicone and/or rubber molding, with strong understanding of:
  • 1+ years of experience in High Consistency Rubber (HCR) molding.
  • 1+ years of experience in Compression and transfer molding.
  • 1+ years of experience in Cure cycles, post-cure and material behavior.

• Experience with Solid Works or other 3D modelling software.
• Experience with mold flow analysis (or ability to interpret results).
• Background in medical, automotive, aerospace or industrial silicone components.
• Experience supporting APQP, PPAP and customer audits.
• Experience with automation, vision inspection and deflashing/trimming technologies.
• Background with adhesion/bonding techniques, multi-shot molding and overmolding.
• RJG/Paulson certification or silicone-specific molding training.
• Familiarity with ISO
  13485 and clean room procedures would be beneficial.
• Experience using DOE, SPC and statistical tools for process improvement.
• Strong ability to interpret engineering drawings, GD & T, CAD models, customer and regulatory specifications.
• Demonstrated success in troubleshooting complex molding issues.