Senior Molding Process Engineer; Aerospace

Acara Solutions is seeking a Senior Molding Process Engineer to work with our client in Everett, WA.

• Salary range: $170,000 – $180,000 annually
• Comprehensive benefits package including medical, dental, vision, paid time off, paid holidays, and 401(k) with company match

This is a salaried, full-time direct hire opportunity within the aerospace industry. This role is responsible for overseeing the technical and manufacturing aspects of injection molding operations, with a focus on improving production output, product quality, and overall process efficiency. The position will drive process optimization initiatives to reduce scrap, rework, and cycle time while supporting new product introductions.

• Provide sustaining process engineering support for plastic injection molding operations
• Optimize existing molding processes through data-driven experimentation and analysis
• Develop and implement new molding programs for new product launches
• Reduce setup time, scrap, cycle time, and overall process waste
• Lead pilot runs and test activities to validate mold and design changes
• Partner with Quality to ensure molded components meet drawing and specification requirements
• Support molding transfer activities in collaboration with project management teams
• Interface with customers during on-site pilot runs and process qualification efforts
• Train and mentor process technicians and press operators on best practices
• Recommend tooling and mold design improvements to enhance manufacturability
• Troubleshoot and resolve dimensional and process-related issues
• Initiate and support Engineering Change Orders (ECOs) for process and design improvements
• Coordinate repair and maintenance of tooling with internal teams and/or customers
• Implement injection molding best practices across operations and support continuous improvement initiatives
• Provide support to other manufacturing processes as needed

• Bachelor’s degree in Plastics Engineering or related field
• Minimum 5 years of experience in injection molding, including hands‑on knowledge of molding methods, equipment, and processes
• Minimum 2 years of project management or project coordination experience
• Experience with process optimization, troubleshooting, and production support in a manufacturing environment
• Must be a U.S. Person (ITAR requirement)

• RJG Master Molder certification
• Lean Six Sigma training or certification (Green Belt, Black Belt)
• Experience with SMED and other lean manufacturing methodologies
• CAD proficiency or design-for-manufacturing (DFM) experience