Principal, Molding & Tooling Engineering

Alcon; Chesapeake (OH); On-site; USD 110,000 - 160,000; Full time

Job summary

Alcon is seeking a Principal, Molding & Tooling Engineering to lead strategic molding initiatives. You will drive design and optimization of mold tooling, support NPI from concept through ramp-up, and partner with global teams to improve throughput and quality while meeting regulatory requirements.

The role focuses on precision tooling, DOE, process validation (IQ/OQ/PQ), and mentoring engineers, with onsite work hours and travel up to 10%. Relocation is available; sponsorship is not.

Qualifications

• Bachelor's degree in Engineering or equivalent with related experience.
• Strong understanding of scientific molding principles and injection molding processes.
• Experience with molding process validation/qualification IQ/OQ/PQ.
• Hands-on with hot runner systems and troubleshooting.
• Experience in regulated medical device environments is a plus.

Responsibilities

• Design and develop precision mold tooling and optimize injection molding processes for efficiency, reliability, and part quality.
• Lead and approve improvements and validations for injection molds, tooling support systems, and molding equipment.
• Provide technical guidance during mold maintenance, qualification, and machine/equipment troubleshooting.
• Investigate process issues and implement advanced improvements in tooling design and manufacturing techniques.
• Define and optimize molding processes through capability studies, DOE, root cause analysis, and validation activities (IQ/OQ/PQ).
• Oversee molding trials, process documentation, and assessments of raw material impacts on molding performance.
• Collaborate with cross-functional partners to reduce defects, enhance mold performance, and elevate production throughput.
• Scout and evaluate advanced tooling technologies and auxiliary equipment to drive safety, efficiency, and cost savings.
• Recommend capital investments, support tooling standardization, and write capital justifications.
• Support New Product Introduction (NPI) from concept through production ramp-up, managing timelines, risks, and cost targets.

Skills

Injection molding

Mold tooling design

DOE / capability studies

IQ/OQ/PQ validation

Regulatory compliance

Education

Bachelor's degree in Engineering

Tools

Mold tooling equipment

Hot runner systems

Automation tooling (EOA)

Job description

At Alcon, we're passionate about enhancing sight and helping people see brilliantly. With more than 25,000 associates, we innovate fearlessly, champion progress, and act swiftly to impact global eye health. We foster an inclusive culture, recognizing your contributions and offering opportunities to grow your career like never before. Together, we make a difference in the lives of our patients and customers. Are you ready to join us?

This role is part of Alcon's Engineering function, a team focused on improving quality, processes, products, packaging and materials across our business to help deliver brilliant outcomes.

The Principal, Molding & Tooling Engineering (Science/Tech/Engineering Path) leads strategic and technical initiatives related to injection molding processes, mold/tooling design, and manufacturing optimization. You will serve as a subject matter expert (SME) for molding and tooling, driving innovation, improving throughput, and supporting New Product Introduction (NPI) and continuous improvement across global operations, including the design, development, and transfer (from R&D) of mold tooling and molding processes suited to part geometry, material properties, production volume, and cost efficiency, while troubleshooting molding issues, enhancing automation performance, implementing quality controls, and ensuring reliable production of molded plastic components.

Specifics Include:

• Design and develop precision mold tooling and optimize injection molding processes for efficiency, reliability, and part quality

• Lead and approve improvements and validations for injection molds, tooling support systems, and molding equipment

• Provide technical guidance during mold maintenance, qualification, and machine/equipment troubleshooting

• Investigate process issues, and implement advanced improvements in tooling design and manufacturing techniques

• Define and optimize molding processes through capability studies, DOE, root cause analysis, and validation activities (IQ/OQ/PQ)

• Oversee molding trials, process documentation, and assessments of raw material impacts on molding performance

• Collaborate with cross-functional partners to reduce defects, enhance mold performance, and elevate production throughput

• Scout and evaluate advanced tooling technologies and auxiliary equipment to drive safety, efficiency, and cost savings

• Recommend capital investments, support tooling standardization, and write capital justifications

• Support New Product Introduction (NPI) from concept through production ramp-up, managing timelines, risks, and cost targets

• Partners with suppliers, contract manufacturers, and global teams to ensure robust solutions across the product lifecycle

• Mentor junior engineers and technicians on best practices in molding, tooling, and process development

• Ensure all tooling designs and molding processes meet regulatory, safety, and quality requirements for medical devices

• Maintain documentation, change control, and quality compliance across internal and external systems

• Uphold GxP requirements by following SOPs, maintaining accurate documentation, and ensuring rigorous quality control

• Contribute to a culture of continuous improvement and operational excellence

WHAT YOU'LL BRING TO ALCON:

• Bachelor's Degree or Equivalent years of directly related experience (or high school +13 yrs; Assoc.+9 yrs; M.S.+2 yrs; PhD+0 yrs)

• The ability to fluently read, write, understand and communicate in English

• 5 Years of Relevant Experience

• Work Hours: Exempt: 40 hours per week: Monday - Friday, 8:00 AM EST - 5:00 PM EST

• Travel Requirements: Up to 10%

• Location: Onsite

• Relocation is Available

• Sponsorship is Not Available

PREFERRED QUALIFICATIONS/SKILLS/EXPERIENCE:

• Degree in Engineering (Plastics or Mechanical Engineering strongly preferred but open to other disciplines)

• Strong understanding of scientific molding principles

• Proven experience troubleshooting and optimizing injection molding processes and equipment

• Experience performing molding process validation and qualification (IQ/OQ/PQ)

• Hands-on experience with hot runner systems and hot runner troubleshooting

• Experience troubleshooting automation, including end-of-arm (EOA) tooling

• Experience with process monitoring systems

• Experience with contact and non-contact dimensional inspection

• Industry experience in medical device manufacturing or other regulated environments

HOW TO THRIVE AT ALCON:

• Collaborate with teammates to share standard processes and learnings as work evolves!

• See your career like never before with focused growth and development opportunities!

• Join Alcon's mission to provide outstanding, innovative products and solutions to improve sight, improve lives, and grow your career!

• Alcon provides a robust benefits package including health, life, retirement, flexible time off for exempt associates, PTO for hourly associates, and much more!

Alcon Careers:

• See your impact at alcon.com.careers