Senior Process Engineer

US Conec • Fort Worth, TX

24d • Onsite

About The Position

The Senior Process Engineer is responsible for developing, optimizing, and troubleshooting injection molding processes to ensure efficient, high-quality, and cost-effective production. This role requires working with cross-functional teams to improve process stability, reduce waste, and drive continuous improvement initiatives. The engineer will play a key role in tooling qualifications, process standardization, and developing best practices in molding operations.

Requirements

• Bachelor’s degree in Mechanical engineering, Plastics engineering, or a related field.
• 7+ years of experience in injection molding process development, tooling, and manufacturing with a focus on tight tolerance, precision injection molding.
• Formal Master Molder or similar training RJG, AIM, etc. a strong plus
• Strong understanding of polymer materials, mold construction, and processing parameters with a focus on engineering grade resins including PEI, PBT, and PC/ABS.
• Expertise in scientific molding techniques, mold flow analysis, and process validation methodologies.
• Hands-on experience with injection molding machines, robotics, and automation systems.
• Familiarity with lean manufacturing principles, Six Sigma methodologies (Green/Black Belt preferred), and SPC.
• Proficiency in troubleshooting molding defects such as flash, short shots, burns, warpage, and splay.
• Strong analytical, problem-solving, and project management skills.
• Demonstrated ability to make data-driven decisions using data analysis tools and techniques.
• Effective communication and teamwork abilities for cross-functional collaboration.

Responsibilities

• Develop, implement, and optimize injection molding processes to improve efficiency, quality, and cycle times.
• Troubleshoot and resolve molding defects, tooling issues, and process variations using root cause analysis techniques.
• Utilize scientific molding principles and process optimizations tools including Design of Experiments to establish capable and consistent molding processes.
• Assist with new production equipment installation and qualification, providing feedback on suitability, performance and reliability.
• Lead process development for tool qualifications and test runs supporting both new product introductions and capacity tooling.
• Work closely with tooling engineers, maintenance teams, and production staff to enhance mold performance and longevity.
• Standardize process documentation, including work instructions, SOPs, and process sheets.
• Implement continuous improvement projects focused on cycle time reduction, scrap reduction, and process efficiency.
• Research and recommend new molding technologies, automation, and auxiliary equipment to enhance production capabilities.
• Provide technical leadership and training to engineers, technicians, and production personnel.
• Ensure compliance with all quality standards and company policies.
• Actively represent the processing capability during mold design reviews and DFM evaluations to insure processing consideration are included in the tooling design cycle.
• Provide on-site support for tooling trials and evaluations at tooling vendors
• Recommend resins and additive packages to support product performance requirements and manufacturing needs while insuring all material-based safety protocols and PPE needs are understood and met.

Benefits

• Competitive base salary with performance-based bonus potential
• 4 weeks of PTO to relax and recharge
• Health, dental, and vision plans to support you and your family
• 401(k) retirement savings plan with employer match and planning resources
• Paid holidays and employee recognition programs
• Opportunities to work with advanced molding technologies and infrastructure systems
• STEM outreach and community engagement initiatives

What This Job Offers

• Job Type: Full-time
• Career Level: Senior