Principal Engineer- Design for Manufacturing

Ingersoll Rand

Lincolnshire (IL)

On-site

USD 100,000 - 150,000

Full time

3 days ago

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Benefits offered by this job

Health insurance

401(k) plan

Employee stock grant

Job summary

Ingersoll Rand is seeking a Principal DFM Engineer to drive design-for-manufacturability for silicone and elastomer-based products. You will lead DFM, cost modeling, and tooling decisions from prototype through production, shaping design, tooling, and process strategies across the Elastomers Operation Unit.

The role emphasizes cross-functional leadership, regulatory readiness for medical device environments, and mentorship of engineers, with a focus on LSR, HCR molding, extrusion, and cost

Qualifications

Bachelor’s degree in Engineering (Mechanical, Manufacturing, Materials, Polymer or similar).
10+ years of elastomer manufacturing, DFM or process engineering experience.
Deep expertise in Silicone (LSR/HCR) and rubber materials; molding processes.

Responsibilities

Lead comprehensive DFM evaluations for elastomer components and assemblies; optimize manufacturability, yield, and cost.
Own technical costing and quotation leadership; develop cost models from prototype to production.
Define end-to-end tooling and manufacturing strategies including prototyping, tooling phases, automation, and validation roadmap.
Mentor engineers in DFM, elastomer processing, and cost engineering; support capability development.

Skills

Elastomer processing

DFM

Cost modeling

Process engineering

Education

Bachelor's degree in Engineering

Tools

SolidWorks

Job description

About Us

Imagine a company with technology leadership of over 160 years, yet it operates with the energy of a startup. Ingersoll Rand has dedicated itself to Making Life Better for its employees, customers, shareholders, and planets. We produce innovative and mission-critical flow creation and life science technologies – from compressors to precision handling of liquids, gasses, and powers – to increase industrial productivity, efficiency, and sustainability. Supported by over 80+ brands, our products are used in various end-markets including life sciences, food and beverage, clean energy, industrial manufacturing, infrastructure, and more. Across the globe, we’re driving growth with an entrepreneurial spirit and ownership mindset. Learn more at irco.com and join us to own your future.

Job title

Principal DFM Engineer

Location

Lincolnshire, IL

About Us

Job Overview

The Principal DFM Engineer is responsible for driving design-for-manufacturability (DFM), process feasibility, and cost optimization for silicone and elastomer-based products across the organization.

This role serves as a subject matter expert and strategic leader, owning the quoting process from a technical standpoint while establishing the manufacturing strategy from prototype through full-scale production.

The Principal DFM Engineer plays a critical role in guiding cross-functional decision-making and influencing customer outcomes, directly impacting business growth, margin performance, and long-term capability development. While accountable for quotation and cost modeling, this position is primarily differentiated by its deep technical influence, shaping product design, tooling, and process strategies across the Elastomers Operation Unit. Additionally, this role advances best practices in LSR, HCR, and elastomer molding and extrusion technologies, particularly within regulated environments including Class II and Class III medical devices, while mentoring engineers and elevating organizational DFM capability.

Responsibilities

Design for Manufacturability (DFM) Leadership
- Lead comprehensive DFM evaluations for elastomer components and assemblies, providing actionable recommendations to optimize:
- Manufacturability and scalability
- Yield, robustness, and quality
- Cost efficiency and margin performance
- Regulatory and validation readiness
- Influence customer designs upstream through direct technical engagement and design reviews
- Identify critical-to-quality features, tolerance risks, and process limitations
- Define optimal manufacturing approaches across:
- LSR injection molding
- HCR molding (compression, transfer)
- Extrusion and downstream operations
- Multi-shot, overmolding, and bonded assemblies
Technical Costing & Quotation Leadership
- Serve as the technical owner of RFQs, developing detailed, transparent cost models for prototype through full production
- Translate DFM decisions into:
- Cycle time, cavitation, and capacity strategies
- Tooling concepts and lifecycle strategies (prototype vs production tooling)
- Labor, material utilization, scrap, and secondary operations
- Develop and present:
- Multi-scenario pricing strategies (volume tiers, automation levels, tooling options)
- NRE, validation (IQ/OQ/PQ), and lifecycle cost considerations
- Partner with Sales and Business Development in customer-facing technical and commercial discussions
- Ensure alignment between technical assumptions, cost structure, and business objectives
Tooling & Manufacturing Process Strategy Development
- Define the end-to-end manufacturing strategy, including:
  - Prototyping approach and scale-up pathway
  - Tooling phases and capital investment strategy
  - Automation and inspection strategies
  - Validation and qualification roadmap
- Define and evaluate tooling approaches:
- Collaborate with Process Engineering, Tooling, Quality, and Operations to:
  - Validate manufacturability assumptions
  - Optimize cycle time, yield, and throughput
- Drive early-stage decisions that impact long‑term operational efficiency, cost, and capacity
Cross‑Functional Technical Leadership
- Act as a technical bridge across:
  - Sales / Business Development
  - Engineering (Process, Tooling, Project)
  - Quality (validation, regulatory requirements)
  - Supply Chain (materials, MOQs, lead times)
- Lead technical reviews during RFQ, contract review, and NPI phases
- Ensure manufacturability, cost, and quality assumptions are clearly documented and transferred into execution
Continuous Improvement & Cost Optimization
- Drive should‑cost modeling and cost‑out initiatives through improved mold designs, optimized cycle times, or new automation opportunities
- Analyze quote‑to‑actual performance and refine estimating accuracy
- Establish and standardize:
  - DFM guidelines
  - Costing methodologies
  - Quoting best practices and templates
- Identify and implement improvements in:
  - Tool design
  - Process efficiency
  - Material utilization
  - Automation strategies
Technical Mentorship & Organizational Impact
- Mentor and develop engineers in DFM, elastomer processing, and cost engineering
- Serve as a subject matter expert (SME) for silicone and rubber processing technologies
- Support capability development and capital investment planning
- Contribute to long‑term technology roadmaps and strategic growth initiatives

Requirements

Bachelor’s degree in Engineering (Mechanical, Manufacturing, Materials, Polymer, or similar)
10+ years of experience in elastomer manufacturing, DFM or process engineering
Deep expertise in:
- Silicone (LSR, HCR) and rubber materials
- Compression, transfer, and injection molding processes
- Tooling design principles (cavitation, gating, venting, materials)
- Cost modeling and estimating for elastomer components
Proven experience in:
- Validation requirements (IQ/OQ/PQ), APQP, PPAP
- Interpreting engineering drawings, GD&T, and 3D CAD models
- Regulatory and customer specifications (medical preferred)
Experience working in cross‑functional and customer‑facing roles
Proficiency with CAD tools (e.g., SolidWorks)

Preferred

Experience in medical device manufacturing (Class II / Class III)
Experience in technical quoting and cost modeling
Experience with:
- Mold flow analysis and interpretation
- Automation and high‑volume manufacturing systems
- Multi‑material molding (overmolding, bonding, insert molding)
- Experience in CDMO environment
- Six Sigma or Lean Manufacturing certification

Key Competencies

Strong technical and commercial acumen
Advanced problem‑solving and analytical skills
Ability to influence internal and external stakeholders
Excellent communication with both technical and non‑technical stakeholders
High level of ownership, accountability, decision‑making authority
Strategic mindset with attention to detail

Travel & Work Arrangements/Requirements

Fully site based

The pay range for this role is $100-$150k, excluding incentive opportunities. The pay range takes into account a wide range of factors that are considered in making compensation decisions including, but not limited to, skills; experience and training; licensure and certifications; and geographic location. Hired applicant will be eligible to receive (discretionary/nondiscretionary) annual bonuses and incentive compensation.

What We Offer

At Ingersoll Rand, we embrace a culture of personal ownership — taking responsibility for our company, our communities, and our environment, as well as our individual health and well‑being. Our comprehensive benefits package is designed to empower you with the tools and support necessary to take charge of your health, ensuring that together, we can continue to make life better. Our range of benefits includes health care options like medical and prescription plans, dental and vision coverage, as well as wellness programs. Additionally, we provide life insurance, a robust 401(k) plan, paid time off, and even an employee stock grant, among other offerings. These benefits are our commitment to you, so you can be your best at work and beyond.

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