Senior Manufacturing Engineer

We are seeking a Senior Manufacturing Engineer to join our plastic injection molding and medical device manufacturing team. This role is responsible for developing, optimizing, and sustaining robust injection molding processes that meet safety, quality, cost, and delivery goals in a cleanroom, FDA‑regulated environment. While the position is scoped at a senior level, we also welcome intermediate‑level applicants with strong technical capabilities, leadership potential, and a passion for continuous improvement.

The base salary range for this position is $90,000 to $125,000 annually
, depending on qualifications and experience.

• Develop, validate, and optimize injection molding processes for new and existing plastic components, ensuring consistent quality and high‑volume manufacturability.
• Troubleshoot and improve molding process performance by analyzing part defects, cycle inefficiencies, and machine/tool interactions; work hands‑on with tooling engineers and technicians to resolve root causes and implement effective solutions.
• Design and lead productivity, scrap‑reduction, and cycle‑time optimization projects using lean manufacturing, scientific molding, and process engineering tools.
• Collaborate cross‑functionally with Project Engineering, Process Development, Tooling, and Production to ensure manufacturability (DFM), proper material selection, and transfer‑to‑manufacturing readiness.
• Train and mentor production operators, leads, and junior engineers in molding best practices, safety, and technical troubleshooting.
• Develop and maintain clear and effective documentation for manufacturing processes including work instructions, set‑up sheets, and best practice guidelines.
• Collaborate with Automation Engineering on the implementation of automation, robotics, end‑of‑arm tooling (EOAT), or other production‑enhancing technologies.
• Participate in design reviews and provide technical input to ensure that new products are designed with manufacturability, moldability, and tooling efficiency in mind.
• Provide engineering input into preventative maintenance schedules and mold/tooling lifecycle improvements in coordination with tooling and maintenance teams.
• Monitor and interpret process performance data to identify trends and continuous improvement opportunities; assist in conducting capability studies as part of process development.
• Ensure adherence to all safety standards and promote a culture of safety in daily activities and project planning.
• Support validation and quality assurance teams during product launches by contributing technical knowledge and assisting with test set‑up, data collection, and engineering reports.
• Stay current on industry trends, materials, and injection molding technologies to recommend enhancements that drive operational excellence.
• Other responsibilities as assigned.

• Bachelor’s degree in Plastics, Manufacturing, Industrial, or Mechanical Engineering (or related field), or equivalent practical experience.
• 7+ years of progressive engineering experience in injection molding and/or medical device manufacturing (open to 3–6 years for strong intermediate candidates).
• Strong understanding of injection molding machines, tooling design, resin behavior, and process parameters.
• Hands‑on troubleshooting experience with mold startups, part quality issues, and tooling wear.
• Proficient in CAD tools (e.g., Solid Works), with the ability to review mold designs and tooling drawings.
• Experience with mold flow/simulation software (e.g., Autodesk Moldflow) is preferred.
• Working knowledge of lean manufacturing, 5S, root‑cause analysis, and continuous improvement tools (e.g., A3, Kaizen, Poka‑Yoke).
• Effective project management, time management, and communication skills in cross‑functional environments.
• Experience working in regulated environments (e.g., FDA, ISO 13485), with understanding of quality standards (e.g., SOPs, document control).
• Familiarity with ERP systems (IQMS or similar) and manufacturing data collection tools.
• Professional traits: dependable, collaborative, proactive, self‑aware, and adaptable to change.