Senior Engineer, Moulding Engineering - Research & Technology

resmed; Sydney; On-site; AUD 130,000 - 180,000; Full time

Job summary

ResMed's Moulding Research & Technology Engineering team is seeking a Senior Engineer to lead exploration and maturation of new moulding technologies, with emphasis on Liquid Silicone Rubber (LSR) and related advanced processes. You will translate product and manufacturing needs into experiments, prototypes and proof-of-concept methods.

You will drive technologies from feasibility to production-relevant demonstrations, transfer mature capabilities to NPI teams, and mentor engineers in scientific

Qualifications

• Bachelor's degree in Polymer, Plastics, Rubber, Mechanical, Materials, Manufacturing Engineering or related.
• Hands-on experience in injection moulding process development using scientific moulding.
• 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 concrete solutions.

Responsibilities

• Identify 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.
• Develop 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.
• Work 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.
• Progress 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.
• Work 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.
• Act 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.

Skills

Moulding fundamentals

Scientific moulding

Process development

Structured experiments

Root-cause analysis

Education

Bachelor's degree in Polymer/Plastics/ Rubber/ Mechanical/ Materials/ Manufacturing Engineering

Tools

Injection moulding equipment

Tooling

Materials

Auxiliary systems

Job description

Let's talk about the Team

Join 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 Role

As 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 Responsibilities

Moulding Technology Exploration

Identify 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 Development

Develop 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 Experimentation

Work 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 Scale

Progress 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 Development

Work 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 Leadership

Act 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 you

You 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 Experience

Required

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 c