Blow Molding Process Development Engineer

Thermo Fisher Scientific • Rochester, NY

3d • Hybrid

About The Position

As a Blow Molding Process Development Engineer, you will lead the development, optimization, and validation of blow molding processes that support Thermo Fisher Scientific’s portfolio of innovative plastic products used in life science and laboratory applications. You will use your deep technical expertise in Scientific Molding, Design of Experiments (DOE), and process validation to deliver robust, repeatable, and efficient molding processes that meet demanding performance and quality requirements.

Requirements

• Bachelor’s degree or equivalent experience in Plastics Engineering, Mechanical Engineering, Chemical Engineering, or a related area.
• Minimum 7 years of experience in blow molding process development, optimization, and validation.
• Extensive experience with evaluating and selecting mold tooling, plastic resins and processing equipment for blow molding.
• Proven track record of establishing process conditions and solving product quality issues by understanding the relationships of material, product design, tooling, machine and processing conditions.
• Proficiency with Design of Experiments (DOE), process characterization, and statistical analysis tools.
• Experience reviewing product designs to enhance Design for Manufacturability
• Strong analytical, problem-solving, and data-driven decision-making skills.
• Excellent communication and documentation abilities across technical and non-technical team members.
• Demonstrated skill in guiding projects, handling priorities, and achieving outcomes in a dynamic setting.
• Passion for Thermo Fisher Scientific’s mission and strong dedication to quality and continuous improvement.

Nice To Haves

• A Master’s degree or equivalent experience is preferred.
• Knowledge of polymer flow simulation software (e.g., Moldflow, Sigmasoft) is a plus.
• Experience in a regulated manufacturing environment (e.g., medical device, life sciences, or pharma) is highly desirable.

Responsibilities

• Lead process development activities for new and existing blow molded products from concept through commercial production.
• Evaluate and select processing equipment for extrusion (EBM) and injection-stretch blow (ISBM) molded products.
• Develop and conduct Design of Experiments (DOE) to evaluate process variables, establish control windows, and identify critical process parameters.
• Partner multi-functionally with tooling, quality, materials, and manufacturing teams to ensure seamless product launch and scale-up.
• Support tooling design and qualification, including review of materials, venting, flash pockets, etc.
• Lead and document process validation activities (IQ/OQ/PQ) in alignment with Thermo Fisher Scientific’s quality systems and industry standards.
• Perform advanced troubleshooting of molding processes and equipment to resolve performance issues and drive continuous improvement.
• Provide technical mentorship and guidance to process technicians and junior engineers.
• Generate detailed technical reports, protocols, and documentation to support validation and regulatory submissions.

Benefits

• A choice of national medical and dental plans, and a national vision plan, including health incentive programs
• Employee assistance and family support programs, including commuter benefits and tuition reimbursement
• At least 120 hours paid time off (PTO), 10 paid holidays annually, paid parental leave (3 weeks for bonding and 8 weeks for caregiver leave), accident and life insurance, and short- and long-term disability in accordance with company policy
• Retirement and savings programs, such as our competitive 401(k) U.S. retirement savings plan
• Employees’ Stock Purchase Plan (ESPP) offers eligible colleagues the opportunity to purchase company stock at a discount

What This Job Offers

• Job Type: Full-time
• Career Level: Senior