Senior Injection Molding Process Engineer

Aegis Worldwide; Anderson (IN); On-site; USD 85,000 - 120,000; Full time

Job summary

Aegis Worldwide is seeking a Process Engineer to lead the optimization of injection molding operations in a hands-on, floor-focused role. You will establish robust process windows for PP/PC resins, define golden settings, and drive defect reduction through data-driven methods.

Responsibilities include training teams, leading analysis of defects, and coordinating with Tool Room, Maintenance, and Quality to sustain process stability and efficiency.

Qualifications

• Bachelor’s degree in Engineering (Plastics, Mechanical, Manufacturing, or related).
• 7-10 years of hands-on injection molding process engineering experience.
• Strong understanding of PP and PC material behavior in molding applications.
• Proven ability to analyze data and solve complex process problems.
• DOE, SPC, and Six Sigma exposure.

Responsibilities

• Establish scientifically validated process windows for PP, PC, and similar resins.
• Define and maintain golden settings based on melt temperature and shear, injection velocity profiles, pack/hold pressure and time, cooling efficiency and mold temperature control.
• Apply viscosity, shrinkage, and crystallization behavior (PP) and thermal sensitivity (PC) to process design.
• Own process setup sheets, standard work, and controlled parameter limits.
• Train and mentor the organization to run and protect molding processes.
• Lead engineering analysis of complex defects (flow hesitation, jetting, sinks, warp, etc.).
• Correlate defects to material condition, mold design, and machine dynamics.
• Use DOE, cavity pressure trends, and SPC data to drive permanent solutions
• Support mold trials, steel-safe changes, and new tool introductions.
• Ensure molds are technically capable of running defined process windows.
• Own molding-related process capability (Cp/Cpk) and implement SPC on critical parameters.
• Transition quality control from inspection-based to process-controlled.

Skills

Injection molding

Process engineering

Data analysis

SPC

DOE

Six Sigma

Lean Manufacturing

Mold design

Troubleshooting

Communication

Education

Bachelor’s degree in Engineering (Plastics, Mechanical, Manufacturing, or related)

Tools

MS Office

MES

Job description

Aegis Worldwide is seeking a Process Engineer to lead the optimization of injection molding operations in a hands-on, floor-focused role. You will establish robust process windows for PP/PC resins, define golden settings, and drive defect reduction through data-driven methods.

Responsibilities include training teams, leading analysis of defects, and coordinating with Tool Room, Maintenance, and Quality to sustain process stability and efficiency.