Principal, Molding & Tooling Engineering

Alcon•Huntington, WV

9d•Onsite

About The Position

This role is part of Alcon's Engineering function, a team focused on improving quality, processes, products, packaging and materials across our business to help deliver brilliant outcomes. The Principal, Molding & Tooling Engineering (Science/Tech/Engineering Path) leads strategic and technical initiatives related to injection molding processes, mold/tooling design, and manufacturing optimization. You will serve as a subject matter expert (SME) for molding and tooling, driving innovation, improving throughput, and supporting New Product Introduction (NPI) and continuous improvement across global operations, including the design, development, and transfer (from R&D) of mold tooling and molding processes suited to part geometry, material properties, production volume, and cost efficiency, while troubleshooting molding issues, enhancing automation performance, implementing quality controls, and ensuring reliable production of molded plastic components.

Requirements

Bachelor’s Degree or Equivalent years of directly related experience (or high school +13 yrs; Assoc.+9 yrs; M.S.+2 yrs; PhD+0 yrs)
The ability to fluently read, write, understand and communicate in English
5 Years of Relevant Experience

Nice To Haves

Degree in Engineering (Plastics or Mechanical Engineering strongly preferred but open to other disciplines)
Strong understanding of scientific molding principles
Proven experience troubleshooting and optimizing injection molding processes and equipment
Experience performing molding process validation and qualification (IQ/OQ/PQ)
Hands‑on experience 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
Industry experience in medical device manufacturing or other regulated environments

Responsibilities

Design and develop precision mold tooling and optimize injection molding processes for efficiency, reliability, and part quality
Lead and approve improvements and validations for injection molds, tooling support systems, and molding equipment
Provide technical guidance during mold maintenance, qualification, and machine/equipment troubleshooting
Investigate process issues, and implement advanced improvements in tooling design and manufacturing techniques
Define and optimize molding processes through capability studies, DOE, root cause analysis, and validation activities (IQ/OQ/PQ)
Oversee molding trials, process documentation, and assessments of raw material impacts on molding performance
Collaborate with cross‑functional partners to reduce defects, enhance mold performance, and elevate production throughput
Scout and evaluate advanced tooling technologies and auxiliary equipment to drive safety, efficiency, and cost savings
Recommend capital investments, support tooling standardization, and write capital justifications
Support New Product Introduction (NPI) from concept through production ramp-up, managing timelines, risks, and cost targets
Partners with suppliers, contract manufacturers, and global teams to ensure robust solutions across the product lifecycle
Mentor junior engineers and technicians on best practices in molding, tooling, and process development
Ensure all tooling designs and molding processes meet regulatory, safety, and quality requirements for medical devices
Maintain documentation, change control, and quality compliance across internal and external systems
Uphold GxP requirements by following SOPs, maintaining accurate documentation, and ensuring rigorous quality control
Contribute to a culture of continuous improvement and operational excellence