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Job Overview:
The Molding Engineer is 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 Molding Engineer collaborates closely with the Tooling, Production, Quality, NPI and Maintenance teams to ensure successful product launches, consistent quality and efficient manufacturing processes.
Responsibilities:
Develop, validate, and optimize LSR and HCR molding processes (injection, compression, transfer) using scientific molding principles and DOE methodologies. Establish robust process parameters, including injection/fill profiles, pack/hold strategies, cure cycles, and thermal controls to improve capability (Cp/Cpk) and reduce variation. Troubleshoot complex molding defects (flash, short shots, voids, knit lines, shrinkage, dimensional variation, and cure issues) using structured root cause analysis and corrective actions. Partner with tooling and maintenance teams to qualify molds, optimize gate/vent designs, improve thermal management, and ensure validated equipment performance. Drive continuous improvement initiatives focused on cycle time reduction, scrap minimization, OEE improvement, material yield optimization, and Lean/Kaizen implementation. Support New Product Introduction (NPI) through feasibility assessments, mold trials, process qualification, production launch, and transition to manufacturing. Develop and maintain process documentation, standardized parameter sheets, work instructions, and SPC-based process monitoring while training operators and technicians on best practices. Collaborate cross-functionally with Engineering, Production, Quality, and Estimating teams to improve manufacturability, manage process changes, and ensure quality, customer, and business objectives are achieved.
Requirements:
Bachelor's degree in an Engineering (Mechanical, Manufacturing, Materials, Plastics, Polymer)5+ years' direct experience in silicone and/or rubber molding
Competences:
- Liquid Silicone Rubber (LSR) injection.
- High Consistency Rubber (HCR) molding.
- Compression and transfer molding.
- Cure cycles, post-cure and material behavior.
- Tool design elements (cavitation, gating, venting, steel types).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.
- Preferences:
- Experience with SolidWorks 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 over molding.
- RJG/Paulson certification or silicone-specific molding training.
- Familiarity with ISO13485 and clean room procedures would be beneficial.
