Principal Injection Molding Tooling Architect

Alcon USA•Huntington, WV

5d•Onsite

About The Position

As the Principal Injection Molding Tooling Architect within Alcon's Engineering organization, you will be the primary expert for molding and tooling across global operations. This role involves reviewing capability studies, assessing tool performance, leading validation activities, consulting on troubleshooting, and managing capital justifications. You will also partner with suppliers and contract manufacturers, mentor junior engineers, and ensure compliance with GxP and medical device quality requirements.

Requirements

Bachelor’s Degree or equivalent directly related experience: high school plus 13 years, Associate’s plus 9 years, M.S. plus 2 years, or PhD plus 0 years
Ability to read, write, understand, and communicate fluently in English
5 years of relevant experience

Nice To Haves

Degree in Engineering; Plastics or Mechanical strongly preferred, other disciplines welcome
Deep knowledge of scientific molding principles
Proven track record troubleshooting and optimizing injection molding processes and equipment
Experience executing molding process validation and qualification IQ OQ PQ
Hands on familiarity with hot runner systems and hot runner troubleshooting
Experience troubleshooting automation, including end of arm EOA tooling
Experience with process monitoring systems
Experience with contact and non contact dimensional inspection
Background in medical device manufacturing or other regulated environments

Responsibilities

Design and develop precision mold tooling and optimize injection molding processes for efficiency, reliability, and superior part quality
Lead and approve improvements and validations for injection molds, tooling support systems, and molding equipment
Provide expert guidance for mold maintenance and qualification, and troubleshoot molding machines and related equipment
Investigate process excursions and implement advanced enhancements in tooling design and manufacturing methods
Define and optimize molding processes through capability studies, DOE, root cause analysis, and validation activities including IQ OQ PQ
Oversee molding trials, author process documentation, and evaluate how raw material variation affects molding performance
Collaborate with cross functional teams to lower defect rates, improve mold performance, and raise production throughput
Scout and assess advanced tooling technologies and auxiliary equipment to improve safety, efficiency, and cost
Recommend capital investments, support tooling standardization, and write capital justifications
Support New Product Introduction from concept through ramp up, managing timelines, risks, and cost targets
Partner with suppliers, contract manufacturers, and global teams to ensure robust solutions across the product lifecycle
Mentor junior engineers and technicians in molding, tooling, and process development best practices
Ensure tooling designs and molding processes meet regulatory, safety, and quality expectations for medical devices
Maintain documentation, change control, and quality compliance across internal and external systems
Uphold GxP by following SOPs, keeping accurate documentation, and ensuring rigorous quality control
Contribute to a culture of continuous improvement and operational excellence