Senior Engineer, Moulding Engineering – Research & Technology

ResMed Inc; Sydney; On-site; AUD 140,000 - 190,000; Full time

Job summary

ResMed Inc is seeking a Senior Engineer, Moulding Engineering – Research & Technology to lead exploration and maturation of new moulding technologies, with a focus on Liquid Silicone Rubber (LSR). You will translate product needs into experiments, prototypes and scalable processes, taking technologies from proof-of-concept to production readiness.

You will combine moulding fundamentals with materials, tooling and manufacturing systems to build robust, scalable solutions and transfer mature tech

Qualifications

• Bachelor’s degree in Polymer, Plastics, Rubber, Mechanical, Materials, Manufacturing Engineering or a related discipline.
• Significant hands-on experience in injection moulding process development using scientific moulding principles.
• Strong understanding of injection moulding equipment, tooling, materials and auxiliary systems.
• Experience developing and troubleshooting moulding processes in a manufacturing or development environment.
• Ability to design structured experiments and analyse process data.
• Strong problem-solving and root-cause analysis skills.
• Ability to translate loosely defined technical challenges into clear experiments and development plans.
• Strong technical communication and cross-functional collaboration skills.
• Curious, independent, innovative and comfortable working through technical uncertainty.

Responsibilities

• Moulding Technology Exploration: Identify and evaluate emerging moulding materials, processes, tooling technologies and manufacturing methods.
• Process & Material Development: Develop and characterise new moulding processes, materials and process windows.
• Tooling & Rapid Experimentation: Work closely with Tooling Design to develop experimental moulds and rapid tooling approaches.
• Technology Maturation & Design for Scale: Progress promising technologies toward production-relevant demonstrations.
• Cross-Functional Technology Development: Collaborate with Product Development, Tooling, Automation, Materials, NPI and Quality teams.
• Technical Leadership: Act as a moulding SME and mentor engineers in scientific moulding and process development.

Skills

Structured experiments

Process data analysis

Cross-functional collaboration

Scientific moulding principles

Problem solving

Education

Polymer/Plastics/Materials/Mechanical Engineering degree

Tools

Mould flow simulation

Rapid tooling

Injection moulding equipment

Job description

Let’s talk about the TeamJoin our Moulding Research & Technology (R&T) Engineering Team and help develop the manufacturing capabilities needed for future Resmed products.The R&T team explores and matures new moulding technologies before they enter formal NPI delivery. We work across materials, moulding processes, tooling, automation and product design to solve emerging manufacturing challenges and build scalable technology platforms.Let’s talk about the RoleAs a Senior Engineer, Moulding Engineering – Research & Technology , you will lead the exploration, development and maturation of new moulding technologies, with a strong focus on Liquid Silicone Rubber (LSR) and related advanced manufacturing processes.You will translate future product and manufacturing needs into technical experiments, prototypes and proof-of-concept processes.The role focuses on taking technologies from early feasibility through production-relevant demonstration, then transferring mature technologies to NPI teams for product-specific industrialisation and validation.You will combine scientific moulding principles, material knowledge and hands-on experimentation to build deeper understanding of process behaviour and develop robust, scalable manufacturing solutions.Let’s Talk About ResponsibilitiesMoulding Technology ExplorationIdentify and evaluate emerging moulding materials, processes, tooling technologies and manufacturing methods.Develop proof-of-concept processes to test new ideas and manufacturing concepts.Use scientific moulding principles and structured experiments to understand process behaviour, material interaction and failure mechanisms.Assess technical feasibility, benefits, limitations and risks before recommending further development.Process & Material DevelopmentDevelop and characterise new moulding processes, materials and process windows.Understand the relationship between material properties, tool design, moulding parameters and product performance.Explore technologies that can improve quality, productivity, sustainability and manufacturing flexibility.Develop methods that reduce process complexity, secondary operations and energy consumption where practical.Tooling & Rapid ExperimentationWork closely with Tooling Design to develop experimental moulds, inserts and rapid tooling approaches.Use rapid prototyping and modular tooling concepts to shorten development cycles.Support tool trials and use experimental data to improve mould, product and process design.Apply simulation and engineering analysis where they can accelerate learning.Technology Maturation & Design for ScaleProgress promising technologies from laboratory feasibility toward production-relevant demonstrations.Evaluate technologies against future manufacturing needs including quality, cycle time, scalability, reliability, cost and sustainability.Identify technical gaps that need to be resolved before NPI adoption.Develop reusable moulding principles, standards and technology platforms where possible.Support NPI teams during early adoption while enabling them to own product-specific industrialisation and process validation.Cross-Functional Technology DevelopmentWork closely with Product Development, Tooling, Automation, Materials, NPI and Quality teams.Influence product and tooling concepts early to improve manufacturability and scalability.Share technical learning across teams and manufacturing sites.Technical LeadershipAct as a moulding subject matter expert and mentor engineers in scientific moulding and process development.Promote structured experimentation and evidence-based decision making.Build reusable engineering knowledge and strengthen Resmed’s long-term moulding capability.Let’s talk about youYou are a curious and hands-on engineer who enjoys solving problems that do not yet have established solutions.You are comfortable experimenting, challenging assumptions and learning through iteration.You combine strong moulding fundamentals with an understanding of materials, tooling and manufacturing systems.You also understand that successful R&T is not only about proving that something can work once. It is about developing enough technical understanding so that the technology can later become a robust and scalable manufacturing capability.Let’s talk about Qualifications and ExperienceRequiredBachelor’s degree in Polymer, Plastics, Rubber, Mechanical, Materials, Manufacturing Engineering or a related discipline.Significant hands-on experience in injection moulding process development using scientific moulding principles.Strong understanding of injection moulding equipment, tooling, materials and auxiliary systems.Experience developing and troubleshooting moulding processes in a manufacturing or development environment.Ability to design structured experiments and analyse process data.Strong problem-solving and root-cause analysis skills.Ability to translate loosely defined technical challenges into clear experiments and development plans.Strong technical communication and cross-functional collaboration skills.Curious, independent, innovative and comfortable working through technical uncertainty.Preferred QualificationsStrong experience in Liquid Silicone Rubber moulding.Experience with thermoplastic injection moulding, multi-material or 2K moulding.Experience with silicone overmoulding, textile overmoulding or other advanced moulding technologies.Experience with mould flow simulation or other process simulation tools.Experience with rapid tooling, prototype moulds or modular tooling concepts.Knowledge of polymer/material characterisation and material-process interactions.Experience working with equipment, material and tooling suppliers.Experience developing technologies from proof of concept through production-relevant demonstration.Medical device or other regulated-industry experience is beneficial, although ownership of manufacturing process validation is not a core requirement for this R&T role.What Success Looks LikeSuccess in this role means:Rapidly determining which moulding technologies are worth pursuing.Building deeper technical understanding of new materials and processes.Reducing technical uncertainty before NPI adoption.Developing reusable moulding technologies rather than one-off project solutions.Influencing product and tooling design early to improve manufacturability.Transferring mature technology into NPI with clear evidence, process knowledge and risks.Building manufacturing capabilities that enable future Resmed products.Joining us is more than saying “yes” to making the world a healthier place. It’s discovering a career that’s challenging, supportive and inspiring. Where a culture driven by excellence helps you not only meet your goals, but also create new ones. We focus on creating a diverse and inclusive culture, encouraging individual expression in the workplace and thrive on the innovative ideas this generates. If this sounds like the workplace for you, apply now! We commit to respond to every applicant.