Process Engineer - Injection Molding & Process Optimization

LeoForce; Lynchburg (VA); On-site; USD 90,000 - 115,000; Full time

Benefits offered by this job

Medical insurance

Dental insurance

Vision insurance

401K plan

Paid time off

Job summary

LeoForce is seeking a hands-on Process Engineer in Lynchburg, VA, with strong injection molding experience to develop, optimize, and troubleshoot molding processes in a fast-paced manufacturing environment.

The role focuses on process stability, quality, productivity, scrap reduction, and new mold/product launches. Candidates should solve root causes on the production floor and mentor technicians.

Qualifications

• 3–5+ years in injection molding process engineering or development.
• Bachelor-level degree in plastics/ manufacturing/ mechanical engineering or related field.
• Strong knowledge of thermoplastics, molds, cooling, and hot runners.

Responsibilities

• Develop, validate, and optimize injection molding processes.
• Lead mold trials, sampling, qualification, and production launches.
• Establish process windows based on materials, molds, and equipment capabilities.
• Troubleshoot defects: short shots, flash, burns, splay, warpage, sinks, voids, weld lines, dimensional variation.
• Identify root causes related to equipment, molds, materials, methods, and processing conditions.
• Improve cycle times, scrap, startup waste, downtime, and overall efficiency.
• Develop process docs, setup sheets, troubleshooting guides, and standard work.
• Support PFMEAs, control plans, DOE, corrective actions, and process validations.
• Analyze data to identify continuous improvement opportunities.

Skills

Injection molding

Root-cause analysis

Problem solving

Education

Bachelors in Plastics/Mechanical/Manufacturing Engineering

Job description

LeoForce is seeking a hands-on Process Engineer in Lynchburg, VA, with strong injection molding experience to develop, optimize, and troubleshoot molding processes in a fast-paced manufacturing environment.

The role focuses on process stability, quality, productivity, scrap reduction, and new mold/product launches. Candidates should solve root causes on the production floor and mentor technicians.