Field Controls Engineer

The Senior Field Controls Engineer is responsible for providing advanced technical services and software solutions for rubber and silicone injection molding machinery. This role emphasizes the design, development, programming, integration, commissioning, and optimization of control systems. The position demands deep expertise in PLC programming and injection molding processes, with the ability to work independently at customer sites while maintaining high standards of safety, quality, and customer satisfaction.

• Analyze customer requirements, define problems, evaluate feasibility, and develop innovative software and control solutions for injection molding systems.
• Independently design, program, test, and commission control system software, including logic development, data acquisition, HMI interfaces, and motion control.
• Integrate software with hardware components such as sensors, actuators, drives, PLCs (primarily Bachmann and B&R systems), safety systems, and third-party automation equipment.
• Implement real-time control algorithms for servo-hydraulic drives, FIFO injection units, and cold runner systems to minimize material waste and maximize throughput.
• Perform comprehensive system testing, validation, troubleshooting, and optimization to ensure reliability, performance, and compliance with industry standards and customer specifications.
• Demonstrate expert-level proficiency in IEC -3 programming languages (Structured Text, Ladder Diagram, Function Block Diagram), C/C , and CoDeSys-based development environments.
• Troubleshoot and optimize software for machine retrofits, ensuring compatibility with rubber/silicone specific parameters like vulcanization cycles and material flow.
• Apply advanced knowledge of rubber/silicone injection molding processes, machine mechanics, hydraulics, and electrical systems to create robust control algorithms and process optimizations.
• Interpret and work from European-style hydraulic schematics, electrical drawings, and technical documentation.
• Provide on-site commissioning, startup assistance, troubleshooting, and customer training as required.
• Deliver remote diagnostic support using REMOs and Smart Wall platforms.
• Support field service teams with software updates and training for installation.

• Bachelor’s degree in electrical engineering, Automation Engineering, Mechatronics, Computer Science, or an equivalent technical discipline preferred.
• 10 years of hands-on experience in industrial automation and controls engineering, with extensive experience in the rubber or silicone injection molding industry strongly preferred.
• Experience with elastomer processing principles and molding machinery components preferred.
• Thorough knowledge of electrical, hydraulic, pneumatic, and mechanical systems used in injection molding equipment.
• Strong analytical and problem-solving skills with a systematic method for diagnosing complex issues.
• Excellent verbal and written communication skills; fluency in English is required, while German language skills are a plus.
• Valid passport and the ability to travel domestically up to 50% and internationally as needed, including extended stays in Germany for training.
• Physical ability to work in manufacturing environments, including standing for up to 12 hours, climbing ladders, and working in elevated or confined spaces.
• Availability of overtime and occasional weekend work to meet project deadlines.
• Skilled in using standard business software (Microsoft Office) and remote diagnostic tools.

• Software engineering background is a plus.
• Mechanical background is a plus.

This position requires 50% yearly domestic travel. When not traveling, it is a fully on-site role. The work environment is a close-knit setting with opportunities for growth and training at the company's Germany headquarters.

This is a Permanent position based out of Hebron, KY.

The pay range for this position is $80000.00 - $115000.00/yr.

4 weeks of PTO (3 weeks of paid sick leave, 1 week of vacation) 13 paid holidays

This is a fully onsite position in Hebron,KY.

This position is anticipated to close on Jan 16, 2026.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 30,000 consultants and more than 4,500 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing due to a disability, please email actalentaccommodation@actalentservices.com for other accommodation options.

Salary : $80,000 - $115,000