Plastic Process Engineer

Position Title: Plastics Process Engineer

Position Overview

We are looking for an experienced Plastics Process Engineer to support, develop, troubleshoot, and optimize our injection molding operations.

This is a hands-on engineering position requiring strong technical knowledge of injection molding processes, Scientific Molding, plastics materials, mold performance, and injection molding equipment.

The ideal candidate will have extensive experience diagnosing complex molding problems, developing and validating molding processes, improving production efficiency, and ensuring consistent part quality. This individual will work closely with production, quality, maintenance, tooling, and manufacturing engineering teams to improve process capability, equipment performance, and overall manufacturing operations.

This is not a traditional desk-based engineering position. The successful candidate will spend significant time on the production floor working directly with injection molding machines, molds, materials, and production personnel to identify problems and implement practical solutions.

Key Responsibilities

Injection Molding Process Development & Optimization

• Develop, establish, document, and optimize injection molding processes.
• Apply Scientific Molding / Scientific Injection Molding principles to develop robust and repeatable processes.
• Establish and optimize process parameters, including injection speed, pressure, transfer position, hold pressure, cooling time, back pressure, and screw recovery.
• Conduct process studies, process validations, capability studies, and molding trials.
• Improve process consistency, repeatability, cycle times, and overall equipment efficiency.
• Develop and maintain standardized molding procedures and process documentation.
• Support new product introductions, mold qualifications, and production launches.

Technical Troubleshooting & Problem Solving

• Serve as the primary technical resource for complex injection molding process issues.
• Troubleshoot molding defects, including short shots, flash, sink, warpage, splay, burn marks, weld lines, dimensional variation, and cosmetic defects.
• Identify root causes of process variation, scrap, downtime, and quality problems.
• Troubleshoot mold-related molding problems, including cooling, venting, gating, hot runners, and filling issues.
• Work with tooling and maintenance personnel to resolve mold and machine-related problems.
• Lead root-cause analysis and corrective action activities.
• Provide technical support during production issues and process-related equipment downtime.

Plastics Materials & Resin Knowledge

• Apply knowledge of plastics chemistry, polymers, resins, additives, colorants, and material properties.
• Understand the relationship between material characteristics and injection molding performance.
• Troubleshoot material-related processing issues, including moisture, degradation, contamination, viscosity variation, and material inconsistency.
• Establish and optimize material drying, handling, and processing requirements.
• Evaluate alternative materials and support material qualification and validation.
• Work with material suppliers to resolve technical issues and improve processing performance.

Equipment, Molds & Automation

• Troubleshoot injection molding machines, auxiliary equipment, hot runners, and related systems.
• Support mold trials, mold qualifications, and new tooling development.
• Work with the Tool Room Machinist/Maker on mold improvements and tooling modifications.
• Support automation, robotics, and End-of-Arm Tooling (EOAT) integration from a molding-process perspective.
• Identify opportunities to improve equipment reliability, cycle times, and production performance.
• Work with maintenance and engineering teams to improve manufacturing equipment.

Continuous Improvement & Technical Leadership

• Lead process improvement, R&D, and manufacturing optimization projects.
• Develop and implement scrap reduction, cycle time reduction, and productivity improvement initiatives.
• Establish and maintain process control standards.
• Train and develop molding technicians, machine operators, and setup personnel.
• Provide technical direction and support to production teams.
• Maintain accurate technical documentation, process records, and troubleshooting procedures.
• Maintain a strong presence on the production floor.

What We're Looking For

Required Experience

• 7–10 years of hands-on injection molding or plastics processing experience.
• Extensive experience with injection molding process development and optimization.
• Strong expertise in Scientific Molding / Scientific Injection Molding.
• Proven experience troubleshooting complex injection molding problems.
• Strong understanding of injection molding machines, molds, hot runners, and auxiliary equipment.
• In-depth knowledge of plastics, polymers, resins, additives, colorants, and material behavior.
• Experience with process validation, process capability studies, and statistical process control.
• Experience troubleshooting dimensional, cosmetic, and functional molding defects.
• Understanding of mold design, cooling systems, gating, venting, and mold performance.
• Experience supporting new mold development, mold qualifications, and production launches.
• Strong analytical, mechanical troubleshooting, and problem-solving skills.
• Ability to read and interpret engineering drawings and technical specifications.

Preferred Experience

• Experience with automation, robotics, and EOAT.
• Experience with process monitoring and molding data systems.
• Experience with DOE, SPC, and process capability analysis.
• Experience with SolidWorks or similar CAD software.
• Experience with engineering-grade and specialty thermoplastics.
• Experience in a high-volume or technically demanding injection molding environment.

Education

• Bachelor's degree in Engineering required, preferably Plastics, Mechanical, Manufacturing, Materials Science, or a related discipline.
• Equivalent technical experience may be considered for an exceptionally qualified candidate.

The Right Person Will Be

• Highly technical and hands-on.
• An expert troubleshooter who understands why molding problems occur, not just how to adjust machine settings.
• Strong in Scientific Molding and process development.
• Knowledgeable about plastics materials and their processing characteristics.
• Comfortable working directly on the production floor and with injection molding equipment.
• Analytical, methodical, and focused on identifying root causes.
• Able to develop processes that are repeatable, stable, and capable.
• A strong communicator who can work effectively with production, quality, maintenance, and tooling personnel.
• Self-directed, organized, and able to manage multiple technical projects.

Why This Role Is Different

We are looking for an experienced Plastics Process Engineer who enjoys being directly involved in manufacturing rather than spending the majority of their time behind a desk.

This person will be the go-to technical resource for difficult injection molding, process, material, and production problems.

We need someone who understands Scientific Molding, knows plastics, can diagnose complex processing issues, and can develop practical solutions that improve production performance and product quality.