Sr. Molding Process Engineer

Company & Role Overview

• Our client is a global industrial and life science technology company with a long history of technology leadership, an entrepreneurial culture, and a broad portfolio of brands. Its mission-critical flow creation and life science products serve end-markets including life sciences, food and beverage, clean energy, industrial manufacturing, and infrastructure.

• This role is based in Lincolnshire, IL and is fully onsite.

• The Sr. Molding Engineer owns the development, optimization, and sustaining of robust molding processes for liquid silicone rubber (LSR) and high consistency rubber (HCR), using injection, transfer, and compression molding across all molding work centers.

• The role drives process capability, cycle time, scrap reduction, and production stability, and works closely with the Tooling, Production, Quality, NPI, and Maintenance teams to support successful product launches and consistent quality.

• The pay range for this role is $100,000 to $125,000, based on skills, experience, training, certifications, and geographic location.

Roles & Responsibilities

• Develop, validate, and optimize LSR and HCR molding processes (injection, compression, transfer) using scientific molding principles and DOE methodologies.

• Establish robust process parameters, including injection/fill profiles, pack/hold strategies, cure cycles, and thermal controls, to improve capability (Cp/Cpk) and reduce variation.

• Troubleshoot complex molding defects (flash, short shots, voids, knit lines, shrinkage, dimensional variation, and cure issues) using structured root cause analysis and corrective actions. • Partner with tooling and maintenance teams to qualify molds, optimize gate and vent designs, improve thermal management, and ensure validated equipment performance.

• Drive continuous improvement initiatives focused on cycle time reduction, scrap minimization, OEE improvement, material yield optimization, and Lean/Kaizen implementation.

• Support New Product Introduction (NPI) through feasibility assessments, mold trials, process qualification, production launch, and transition to manufacturing.

• Develop and maintain process documentation, standardized parameter sheets, work instructions, and SPC-based process monitoring, while training operators and technicians on best practices.

• Collaborate cross-functionally with Engineering, Production, Quality, and Estimating teams to improve manufacturability, manage process changes, and achieve quality, customer, and business objectives.

Skills & Requirements

• Bachelor's degree in Engineering (Mechanical, Manufacturing, Materials, Plastics, or Polymer).

• 5+ years of direct experience in silicone and/or rubber molding.

• Hands-on expertise in LSR injection, HCR molding, and compression and transfer molding.

• Working knowledge of cure cycles, post-cure, and material behavior.

• Knowledge of tool design elements, including cavitation, gating, venting, and steel types.

• Experience using DOE, SPC, and statistical tools for process improvement.

• Strong ability to interpret engineering drawings, GD&T, CAD models, and customer and regulatory specifications.

• Demonstrated success in troubleshooting complex molding issues.

• Preferred: Experience with SolidWorks or other 3D modeling software, and mold flow analysis (or ability to interpret results).

• Preferred: Background in medical, automotive, aerospace, or industrial silicone components.

• Preferred: Experience supporting APQP, PPAP, and customer audits.

• Preferred: Experience with automation, vision inspection, and deflashing/trimming technologies.

• Preferred: Background with adhesion/bonding techniques, multi-shot molding, and overmolding. • Preferred: RJG/Paulson certification or silicone-specific molding training.

• Preferred: Familiarity with ISO 13485 and clean room procedures