Plastic Injection Molding Engineer

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. This position is responsible for establishing stable, repeatable, and scientifically controlled processes that produce conforming products while meeting safety, quality, delivery, scrap, and productivity goals.

The ideal candidate will have strong hands-on injection molding experience, a disciplined scientific-molding approach, and the ability to solve root causes rather than rely on temporary adjustments or tribal knowledge. Experience with blow molding is a strong plus.

Essential Duties and Responsibilities

• Develop, validate, document, and maintain robust injection molding processes.
• Establish process windows using scientific molding principles, material characteristics, mold requirements, and equipment capability.
• Lead new mold trials, process development, sampling, qualification, and production launch activities.
• Perform process studies, including fill analysis, gate-seal studies, pressure-loss studies, cooling evaluations, and process-window development.
• Troubleshoot molding defects such as short shots, flash, burns, splay, contamination, dimensional variation, sink, warpage, voids, weld lines, and cosmetic defects.
• Identify and correct root causes involving machines, molds, materials, methods, personnel, and environmental conditions.
• Provide urgent, hands‑on technical support when presses are down or processes become unstable.
• Reduce scrap, downtime, excessive start‑up material, cycle time, and unplanned process adjustments.
• Ensure machines are returned to approved process settings following troubleshooting or maintenance.
• Optimize cycle times without compromising product quality, mold protection, equipment reliability, or validated process requirements.
• Review and approve process changes through the established change‑control and validation processes.
• Support installation and qualification activities, including IQ, OQ, and PQ, when required.
• Develop and maintain process sheets, setup documentation, standard work, troubleshooting guides, and process‑control records.
• Analyze process data, trends, scrap reports, downtime, cavity performance, and production metrics.
• Support PFMEAs, control plans, capability studies, DOE activities, corrective actions, and continuous‑improvement projects.
• Work closely with Production, Quality, Tooling, Maintenance, Materials, Automation, and Project Management.
• Train and mentor Process Technicians, Junior Process Engineers, Setup Technicians, and Production Supervisors.
• Promote the use of documented technical knowledge instead of undocumented, person‑dependent practices.
• Participate in customer, supplier, and regulatory audits as needed.
• Maintain compliance with applicable requirements, including ISO 9001, ISO 13485, AS9100, customer specifications, and internal procedures.
• Follow all safety, housekeeping, environmental, and lockout/tagout requirements.
• Perform other related duties as assigned.

Blow Molding Experience – Preferred

Candidates with blow molding experience will receive additional consideration. Preferred experience includes:

• Extrusion blow molding, injection blow molding, or injection stretch blow molding.
• Parison programming and wall‑thickness control.
• Blow pressure, mold cooling, venting, pinch‑off, flash, and leak‑test optimization.
• Troubleshooting issues such as uneven wall thickness, weak weld lines, distortion, thinning, leaks, and excessive flash.
• Blow molding equipment setup, processing, maintenance coordination, and automation.
• Development and validation of stable blow molding process windows.

Required Qualifications

• Associate or bachelor’s degree in Plastics Engineering, Manufacturing Engineering, Mechanical Engineering, or a related technical field; equivalent hands‑on experience may be considered.
• Minimum of three to five years of injection molding process development or
• Strong understanding of thermoplastic materials, drying requirements, material handling, mold construction, cooling systems, hot runners, and auxiliary equipment.
• Experience with hydraulic, electric, or hybrid injection molding machines.
• 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.
• Ability to work directly on the production floor and respond with urgency to technical problems.
• Strong written, verbal, organizational, and interpersonal skills.
• Working knowledge of Microsoft Office and manufacturing ERP or production monitoring systems.

Preferred Qualifications

• RJG, Paulson, AIM Institute, or equivalent scientific‑molding training.
• Experience with RJG eDART, cavity‑pressure monitoring, or similar processmonitoring technology.
• Blow molding process experience.
• Medical‑device, aerospace, automotive, or other regulated manufacturing experience.
• Experience with IQMS or DELMIAWorks.
• Familiarity with automation, robotics, vision systems, and secondary operations.
• Experience conducting DOE, Gage R&R, capability studies, and molding process validations.
• Lean manufacturing, Six Sigma, or continuous‑improvement experience.

Core Competencies

• Scientific and disciplined approach to processing
• Root‑cause problem‑solving
• Technical urgency and responsiveness
• Process documentation and standardization
• Leadership and mentoring
• Attention to safety and quality
• Accountability and follow‑through

Performance Expectations

Success in this position will be measured through:

• Stable and repeatable molding processes
• Reduced scrap and start‑up waste
• Improved press utilization and uptime
• Reduced unplanned process adjustments
• Faster and more effective troubleshooting
• Achievement of approved cycle times
• Successful new‑tool launches and process validations
• Complete and accurate process documentation
• Improved technical competency of processing personnel
• Compliance with safety, quality, and change‑control requirements

Physical and Work Environment Requirements

• Ability to work in an active manufacturing environment around machinery, heat, noise, resins, molds, and auxiliary equipment.
• Ability to stand and walk for extended periods.
• Ability to climb, bend, reach, and safely access molding equipment.
• Ability to lift up to 50 pounds with or without reasonable accommodation.
• Willingness to provide technical support across shifts when required.
• Required use of applicable personal protective equipment.