Sr Molding Engineer

Job Description Summary

The Molding Engineer is a highly technical role responsible for ensuring injection molded parts are robust, scalable, and compliant with regulatory requirements across all manufacturing sites. This role oversees supplier technical performance and supports all manufacturing sites by driving best-in-class molding technologies, process capability, and validated solutions.

This role provides deep technical oversight of supplier performance, including design-for-manufacturability (DFM), tooling design and fabrication, process optimization, validation, compliance troubleshooting, root cause analysis, and lifecycle management of molds and related assets. Project management and cross-functional collaboration are also key to success. The position reports directly into the Molding & Tooling Engineering Organization ISC team at the Irvine site.

We are the makers of possible

BD is one of the largest global medical technology companies in the world. Advancing the world of health™ is our Purpose, and it’s no small feat. It takes the imagination and passion of all of us—from design and engineering to the manufacturing and marketing of our billions of Med Tech products per year—to look at the impossible and find transformative solutions that turn dreams into possibilities.

We believe that the human element, across our global teams, is what allows us to continually evolve. Join us and discover an environment in which you’ll be supported to learn, grow and become your best self. Become a maker of possible with us.

• Act as the guardian of Design Intent and Design Integrity: ensure molded parts consistently meet form, fit, and function across the full product lifecycle.
• Lead or support the design, development, and validation of molds for plastic, silicone, and rubber components.
• Review and approve final technical documentation (DFMs, mold prints, process sheets, engineering drawings).
• Collaborate with cross-functional teams (Manufacturing, Quality, Procurement, PMO) to ensure project success.
• Partner with suppliers to manage mold validations, modifications, and production performance.
• Troubleshoot molding and related manufacturing processes (injection, LSR, compression/transfer, blow molding, etc.) at the root-cause level.
• Apply advanced statistical methods (DOE, regression, capability studies, SPC) to define process windows, verify process robustness, and reduce variation.
• Use predictive analysis to anticipate risks, confirm long-term reliability, and optimize supplier performance.
• Contribute to sustainability initiatives by reducing waste, improving yield, and supporting energy-efficient practices.
• Provide mentoring, technical guidance, and statistical literacy training to junior engineers and technicians.
• Maintain accurate project records, equipment histories, and process performance data.

• Bachelor’s degree in Engineering (or equivalent experience).
• Minimum of 5 years of relevant experience in molding and tooling.
• Strong knowledge of injection molding (thermoplastics), liquid silicone molding (LSR/LIM), compression/transfer molding, insert and two-shot molding.
• Demonstrated ability to protect design intent through technical rigor, DFM, and data-driven decision making.
• Experience managing supplier relationships, troubleshooting technical issues, and driving process improvements.
• Proficiency in:
  • Microsoft Office (Word, Excel, PowerPoint)
  • CAD (Solid Works, Creo, or equivalent)
  • Injection Molding Simulation (Moldflow [preferred], Sigma Soft, or equivalent)
  • Statistical tools (Minitab [preferred] or equivalent)
• Excellent problem-solving, analytical, and communication skills.
• Strong organizational skills; capable of working independently and in a fast-paced environment.
• Ability to travel domestically and internationally (~25%).

At BD, we prioritize on-site collaboration because we believe it fosters creativity, innovation, and effective problem-solving, which are essential in the fast-paced healthcare industry. For most roles, we require a minimum of 4 days of in-office presence per week to maintain our culture of excellence and ensure smooth operations, while also…