Senior Mechanical Engineer
About The Position
The Senior Mechanical Engineer supports customer quoting, injection mold-tooling development, and new product introduction (NPI) through successful production launch. This hands-on role works with customers, tooling suppliers, and internal manufacturing and quality teams to assess part manufacturability, estimate tooling and production costs, review mold designs, and resolve technical challenges throughout tooling development and production launch. The role requires practical injection molding manufacturing experience, strong problem-solving skills, and the ability to coordinate technical activities independently from initial customer requirements through production readiness. The engineer reviews customer designs and requirements, performs design for manufacturability reviews, and provides technical input on mold and tooling designs. The position leads NPI activities from tooling kickoff through fabrication, sampling, qualification, and production release; evaluates trial samples and inspection results; supports troubleshooting, process optimization, and validation; and identifies opportunities to improve tooling performance, efficiency, quality, and engineering processes. The role requires approximately 20% travel and compliance with applicable regulations and company policies. Due to ITAR and/or CUI compliance, candidates must be a U.S. Citizen, Permanent Resident Alien, or Protected Individual per 8 U.S.C. 1324b(a)(3). Candidates considered for hire must pass a pre-employment background check.
Requirements
- Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, or a related engineering discipline.
- At least 7 years of mechanical or manufacturing engineering experience.
- Practical understanding of injection molding processes, mold tooling design, plastic materials, and design for manufacturability (DFM).
- Ability to evaluate injection-molded parts, mold tooling, and manufacturing processes to identify technical risks and resolve production issues.
- Ability to interpret engineering drawings, 3D CAD models, GD&T, and dimensional inspection results.
- Working proficiency with 3D CAD software such as SolidWorks, Creo, NX, or equivalent for reviewing customer designs and tooling concepts.
- Understanding of injection molding production cost drivers, including tooling complexity, cavitation, cycle times, material utilization, and secondary operations.
- Strong analytical, problem-solving, communication, and organizational skills, including the ability to coordinate technical activities across customers, suppliers, and internal teams.
- Ability to travel approximately 20%.
- Must be a U.S. Citizen, Permanent Resident Alien, or Protected Individual per 8 U.S.C. 1324b(a)(3), due to ITAR and/or CUI compliance.
- Must pass a pre-employment background check.
Nice To Haves
- At least 3 years of experience in injection molding manufacturing, tooling development, or new product introduction.
- Experience with injection mold tooling, manufacturing cost estimation, and production launches.
- Experience supporting tooling development, mold trials, production qualification, and new product launches in a manufacturing environment.
- Experience working with domestic and overseas tooling suppliers.
- Familiarity with quality and manufacturing documentation, inspection methods, and process validation requirements.
- Experience with medical device manufacturing and ISO 8 cleanroom operations.
Responsibilities
- Review customer CAD models, drawings, specifications, and technical requirements to assess manufacturability, tooling feasibility, production costs, and manufacturing risks.
- Support customer quoting by developing tooling and production cost estimates based on part complexity, materials, tolerances, mold cavitation, cycle times, secondary operations, and production volumes.
- Perform design for manufacturability (DFM) reviews of injection-molded parts and proposed mold tooling, working with customers and suppliers to identify and resolve potential manufacturing issues.
- Review mold designs and provide technical input on gate and runner configurations, parting lines, shutoffs, venting, cooling, ejection, mold flow analysis, and inspection requirements.
- Lead NPI activities from tooling kickoff through mold fabrication, sampling, qualification, and production release, coordinating requirements, schedules, and deliverables with customers, suppliers, and internal teams.
- Evaluate tooling trial samples (T-samples), dimensional inspection results, and molding performance, and coordinate corrective actions with tooling suppliers, manufacturing, and quality teams.
- Partner with manufacturing and quality teams to troubleshoot molding defects, dimensional variation, and tooling-related issues, supporting process optimization and production launch.
- Support production validation and qualification activities, including first article inspections, process capability assessments, and IQ/OQ/PQ activities when applicable.
- Collaborate with engineering, sales, manufacturing, quality, and supply chain teams to ensure customer requirements are understood and transitioned into production.
- Identify opportunities to improve tooling performance, manufacturing efficiency, product quality, and engineering processes.
- Adhere to applicable federal and state regulations and company policies, processes, and procedures.
- Perform other duties as requested, directed, or assigned.
Benefits
- Medical, dental, and vision coverage.
- Company-paid basic life/AD&D insurance.
- Short-term and long-term disability insurance.
- Voluntary supplemental insurances.
- Flexible spending accounts.
- Employee assistance program (EAP).
- Sick leave, vacation time, and company-paid holidays as paid time off.
- 401(k) Retirement Savings Plan with a safe harbor non-elective company contribution.
Stand Out From the Crowd
Upload your resume and get instant feedback on how well it matches this job.
What This Job Offers
Job Type
Full-time
Career Level
Senior
