Process Engineer

Theragenics Corp•Sandwich, MA

50d•$120,000 - $150,000

About The Position

Be part of a mission that matters—join Theragenics as a Senior Engineer - Molding Process Development and help drive the production of life-saving medical devices used in cutting-edge treatments. In this critical role, you'll lead plastic molding and overmolding process development from early feasibility through validated production transfer, contributing directly to the creation of minimally invasive solutions that improve and extend lives. If you're passionate about technology, precision, and making a meaningful impact in healthcare, this is your opportunity to help shape the future of patient care. Company Overview: At Theragenics, we're passionate about transforming healthcare and enhancing patient outcomes. Our commitment to innovation drives us to push the boundaries of what's possible, ensuring a brighter future for patients everywhere. Theragenics is a leader in developing medical devices that focus on minimally invasive treatments for cancer, blood vessel procedures, and surgical applications. The company is based in Atlanta, Georgia, and has facilities in Costa Rica, Texas, and Massachusetts. Theragenics proudly operates Arrotek, a visionary medical device design consultancy in the U.S. and Ireland, dedicated to pioneering minimally invasive solutions that enhance lives. Role Summary: As a Senior Engineer - Molding Process Development, you’ll play a pivotal role in driving plastic molding and overmolding process optimization, collaborating with cross-functional teams and external partners to deliver cutting-edge solutions in medical device component manufacturing.

Requirements

Bachelor's Degree in Plastics, Mechanical, Manufacturing, Biomedical Engineering, or a related technical discipline.
Minimum 7 years of relevant experience in injection molding, mold engineering, or medical device manufacturing.
Strong background in scientific molding principles, mold flow analysis (Moldflow, SolidWorks Plastics), and engineering/medical-grade polymers (PEEK, TPU, PC, Nylon).
Familiarity with FDA QSR/QMSR expectations, ISO 13485, process validation, design controls, and risk management.

Nice To Haves

RJG/Paulson or equivalent scientific molding training
hands-on shop-floor mindset
experience with micro-molding or catheter components

Responsibilities

Lead molding process development and DOE-based optimization for plastic injection molded and insert/overmolded medical device components.
Support tooling strategy and mold design reviews (parting line, gating, cooling, steel-safe conditions, etc.) with internal teams and external fabricators.
Specialize in overmolding development onto metal tubes, hypotubes, wireforms, cannulae, and precision medical substrates.
Drive transfer from prototype to production, including T0/T1/T2 sampling, process characterization, and capability analysis.
Own validation deliverables, including IQ/OQ/PQ strategy, protocols, reports, and compliance with FDA/ISO 13485 standards.
Troubleshoot complex molding issues (flash, knit lines, sink, warpage, adhesion) and perform DFM/DFA evaluations with design engineers and customers.
Serve as a primary technical interface with customers on molding feasibility, risks, and validation readiness.