Injection Molding Process Engineer - Scientific Molding

Total Plastic Solutions; Lynchburg (VA); On-site; USD 70,000 - 100,000; Full time

Job summary

Total Plastic Solutions is seeking an experienced Process Engineer to develop, optimize, troubleshoot, and sustain injection molding processes. The role focuses on establishing stable, repeatable, scientifically controlled processes that meet safety, quality, delivery, scrap, and productivity goals.

The ideal candidate will have hands-on experience with injection molding, a disciplined scientific‑molding approach, and strong root‑cause problem solving. Blow molding experience is a strong plus.

Qualifications

• Minimum 3–5 years of injection molding process development.
• Strong understanding of thermoplastics, drying requirements, material handling, mold construction, cooling systems, hot runners, and auxiliary equipment.
• Ability to interpret part drawings, specifications, tolerances, process data, and quality requirements.
• Working knowledge of statistical process control, process capability, root‑cause analysis, and structured problem solving.

Responsibilities

• Develop, validate, document, and maintain robust injection molding processes.
• Establish process windows using scientific molding principles and equipment capabilities.
• Lead mold trials, process development, sampling, qualification, and production launches.
• Perform process studies including fill, gate‑seal, pressure‑loss, and cooling evaluations.
• Troubleshoot molding defects and identify root causes across machines, molds, and materials.
• Provide urgent hands‑on technical support when presses are down or unstable.
• Reduce scrap, downtime, cycle time, and unplanned adjustments.
• Review and approve process changes through change control and validation.

Skills

Injection molding

Root-cause analysis

Scientific molding

Troubleshooting

Process optimization

Cross-functional collaboration

Documentation

Education

Bachelor's degree in Plastics/Manufacturing/Mechanical Engineering

Associate degree with relevant experience

Tools

RJG eDART

IQMS/DELMIAWorks

Process-monitoring tools

Job description

Total Plastic Solutions is seeking an experienced Process Engineer to develop, optimize, troubleshoot, and sustain injection molding processes. The role focuses on establishing stable, repeatable, scientifically controlled processes that meet safety, quality, delivery, scrap, and productivity goals.

The ideal candidate will have hands-on experience with injection molding, a disciplined scientific‑molding approach, and strong root‑cause problem solving. Blow molding experience is a strong plus.