Principal Tooling Design & Polymer Molding SME

Alcon USA•Huntington, WV

7d•Onsite

About The Position

Alcon is hiring a Principal Tooling Design and Polymer Molding SME within its Engineering function. The role sets the technical standard for injection molding and tooling across global operations and connects research and development with manufacturing to support reliable, cost-effective, compliant production. The position designs precision mold tooling and molding processes based on part geometry, material properties, production volume, and cost objectives. It leads improvements and validations for molds, tooling support systems, and equipment, including capability studies, design of experiments, and IQ/OQ/PQ activities. The SME troubleshoots molding and equipment issues, improves automation and end-of-arm interfaces, and strengthens hot runner performance. The role also drives new product introduction from concept through ramp-up, manages timelines, risks, and costs, and partners with suppliers and contract manufacturers. The position mentors junior engineers and technicians, promotes continuous improvement and operational excellence, and ensures designs and processes meet medical-device regulatory, safety, and quality standards. It maintains documentation, change control, and GxP-aligned records in accordance with SOPs. Additional duties include overseeing molding trials, documenting processes, assessing raw-material impacts, collaborating across functions to reduce defects and increase throughput, evaluating advanced tooling and auxiliary equipment, recommending capital investments, standardizing tooling, and preparing capital justifications. This is an onsite, exempt position scheduled for 40 hours per week, Monday through Friday, 8:00 AM to 5:00 PM EST. Travel may be up to 10 percent. Relocation is available; sponsorship is not available.

Requirements

Bachelor’s degree or equivalent experience through one of the stated pathways: high school plus 13 years of experience, an associate degree plus 9 years, an M.S. plus 2 years, or a Ph.D. plus 0 years.
At least 5 years of relevant experience.
Fluent English communication.
Demonstrated experience troubleshooting and optimizing molding processes and equipment.
Experience with molding process validation and qualification, including IQ/OQ/PQ.

Nice To Haves

Engineering degree, preferably with a Plastics or Mechanical emphasis; other disciplines are considered.
Strong command of scientific molding.
Experience with hot runner systems and troubleshooting.
Automation troubleshooting experience, including end-of-arm tooling.
Experience with process monitoring systems.
Experience performing contact and non-contact dimensional inspection.
Industry experience in medical devices or other regulated settings.

Responsibilities

Create precision mold tooling and design molding processes aligned with part geometry, material properties, production volume, and cost objectives.
Lead improvements and validations for molds, tooling support systems, and equipment, including capability studies, design of experiments, and IQ/OQ/PQ.
Troubleshoot molding and equipment issues, improve automation and end-of-arm interfaces, and strengthen hot runner performance.
Drive new product introduction from concept through ramp-up while managing timelines, risk, and cost targets.
Partner with suppliers, contract manufacturers, and cross-functional teams to improve production and product outcomes.
Coach junior engineers and technicians in molding and tooling best practices and champion continuous improvement.
Ensure designs and processes meet regulatory, safety, and quality standards; maintain documentation, change control, and GxP-aligned records per SOPs.
Oversee molding trials, generate process documentation, and assess the effect of raw materials on molding performance.
Scout advanced tooling technologies and auxiliary equipment to improve safety, efficiency, and cost.
Recommend capital investments, standardize tooling, and prepare capital justifications.