Principal, Molding & Tooling Engineering

Alcon USA•Huntington, WV

9d•Onsite

About The Position

The Principal, Molding & Tooling Engineering leads strategic and technical initiatives in injection molding processes, mold and tooling design, and manufacturing optimization. As a subject matter expert, this role drives innovation, improves throughput, and supports New Product Introduction (NPI) and continuous improvement across global operations. The work includes designing, developing, and transferring mold tooling and molding processes from R&D, with consideration for part geometry, material properties, production volume, and cost efficiency. The position also troubleshoots molding issues, improves automation performance, implements quality controls, and supports reliable production of molded plastic components. The role works with cross-functional teams, suppliers, contract manufacturers, and global partners throughout the product lifecycle. It supports NPI from concept through production ramp-up, while managing timelines, risks, and cost targets. The Principal mentors junior engineers and technicians and ensures tooling designs and molding processes meet medical-device regulatory, safety, and quality requirements. The role maintains documentation, change control, and quality compliance, and follows GxP requirements and SOPs. This is an onsite, exempt position with a stated schedule of Monday through Friday, 8:00 AM–5:00 PM EST (40 hours per week). Travel is up to 10%; relocation is available, but sponsorship is not available.

Requirements

Bachelor’s degree or equivalent years of directly related experience; stated alternatives are high school plus 13 years, associate degree plus 9 years, master’s degree plus 2 years, or Ph.D. plus 0 years.
Five years of relevant experience.
Ability to fluently read, write, understand, and communicate in English.

Nice To Haves

Engineering degree; Plastics or Mechanical Engineering is strongly preferred, but other disciplines are considered.
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.
Proficiency in troubleshooting industrial automation equipment, process engineering, and injection molding.
Experience with injection molding machines, including Husky machines.

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 or equipment troubleshooting.
Investigate process issues and implement improvements in tooling design and manufacturing techniques.
Define and optimize molding processes using capability studies, design of experiments (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, improve mold performance, and increase production throughput.
Scout and evaluate advanced tooling technologies and auxiliary equipment to improve safety and efficiency and reduce costs.
Recommend capital investments, support tooling standardization, and prepare capital justifications.
Support NPI from concept through production ramp-up, managing timelines, risks, and cost targets.
Partner with suppliers, contract manufacturers, and global teams to develop 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 requirements for medical devices.
Maintain documentation, change control, and quality compliance across internal and external systems.
Follow SOPs, maintain accurate documentation, and ensure rigorous quality control in accordance with GxP requirements.
Contribute to continuous improvement and operational excellence.