Senior Manufacturing Engineer

MicroAire Surgical Instruments LLC; Charlottesville (VA); On-site; USD 100,000 - 120,000; Full time

Benefits offered by this job

Competitive salary

401(k) with company match

Health, dental & vision insurance

Paid time off & holidays

Career development & Marmon network

Job summary

MicroAire Surgical Instruments LLC in Charlottesville, VA, is seeking a Senior Manufacturing Engineer to lead injection moulding manufacturing, tooling, automation, and process optimization. You will drive DFx, establish molding parameters, support mold design reviews, and lead NPI and DOE studies to ensure production readiness and scalable performance.

The role demands a strong background in plastic injection moulding, hands-on process development, and a passion for Lean, Six Sigma, and

Qualifications

• Bachelor's in Mechanical/Manufacturing Engineering or related field.
• 5+ years in manufacturing engineering, preferably injection moulding.
• Hands-on injection moulding process development and troubleshooting.

Responsibilities

• Lead DFx efforts for injection molded components.
• Develop and optimize molding processes, tooling, fixtures, automation.
• Support mold design reviews and production readiness.
• Lead NPI, DOE studies, IQ/OQ/PQ, and process validation.
• Drive continuous improvement with Lean, Six Sigma, and Kaizen.
• Mentor engineers and technicians.

Skills

Injection moulding

Process optimization

Mold tooling

Statistical analysis

Lean manufacturing

Education

Bachelor’s degree in Mechanical/Manufacturing Engineering

Tools

Automation systems

Robotics

Vision systems

Job description

MicroAire Surgical Instruments LLC

As a part of the global industrial organization Marmon Holdings—which is backed by Berkshire Hathaway—you’ll be doing things that matter, leading at every level, and winning a better way. We’re committed to making a positive impact on the world, providing you with diverse learning and working opportunities, and fostering a culture where everyone’s empowered to be their best.

MicroAire, who we are:

MicroAire Surgical Instruments, (Charlottesville, VA) is a wholly‑owned subsidiary and one of five companies within the Medical Group of Marmon Holdings, a Berkshire Hathaway company. MicroAire is a mid‑sized medical device solutions company with a 45‑year legacy of quality and innovation. With well‑recognised brands, the company is uniquely positioned as a leader in specialty markets, including minimally invasive medical devices and equipment for aesthetics/reconstruction, endoscopic soft tissue release, and orthopedic accessories. MicroAire designs, manufactures, and markets cutting‑edge medical devices that empower surgeons to push the boundaries of surgical precision, delivering safe, efficient, and high‑quality patient outcomes.

Position Summary

The Senior Manufacturing Engineer provides technical leadership for manufacturing operations supporting both existing products and new product introductions, with a strong emphasis on plastic injection molding processes, tooling, automation, and process optimization. This role is responsible for developing, validating, optimizing, and sustaining molding processes and manufacturing systems that improve product quality, scalability, and operational performance. You’ll collaborate cross‑functionally, solve complex challenges, and help shape future manufacturing capabilities through innovation, scientific molding, and continuous improvement.

What You’ll Do

• Lead Design for Manufacturing (DFM) and Design for Assembly (DFA) efforts focused on injection molded components, improving manufacturability, quality, and cost
• Develop, validate, and optimize injection molding processes, tooling, fixtures, automation systems, and secondary operations
• Establish and refine molding parameters (fill, pack, hold, cooling, resin drying, cycle time) using scientific molding principles
• Support mold design reviews, tooling qualification, first article inspection, and production readiness
• Troubleshoot moulding defects such as flash, sink, short shots, warp, splay, burns, and dimensional variation
• Partner with tooling vendors, resin suppliers, and automation integrators to improve mold performance and uptime
• Evaluate and implement advanced manufacturing technologies including robotics, vision systems, and smart manufacturing solutions
• Lead new product introduction (NPI), process validation (IQ/OQ/PQ), DOE studies, and production launch readiness
• Develop scalable manufacturing strategies that support growth, efficiency, and long‑term performance
• Author and maintain key documentation including PFMEA, control plans, work instructions, and process flows
• Lead engineering changes including tolerance analysis, resin evaluation, and mold/process improvements
• Serve as technical lead for complex manufacturing and quality challenges, driving root cause analysis and corrective actions
• Drive continuous improvement using Lean, Six Sigma, Kaizen, and scientific molding methodologies
• Mentor Manufacturing Engineers and Process Technicians, supporting technical growth and capability development
• Partner cross‑functionally with Engineering, Operations, Quality, Supply Chain, and external stakeholders to achieve business objectives

What You Bring

• Required: Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Plastics Engineering, or related field
• 5+ years of manufacturing engineering experience, ideally supporting injection moulding or high‑volume production environments
• Hands‑on experience with injection moulding process development, scientific moulding, tooling validation, and troubleshooting

Preferred

• Experience with automation, robotics, vision systems, or advanced manufacturing technologies
• Knowledge of engineered thermoplastics, resin behaviour, and mold flow principles

Technical Expertise

• Deep understanding of injection moulding processes, tooling design, and process optimisation
• Strong troubleshooting capability across moulding defects, cycle optimisation, and process stability
• Experience with validation (IQ/OQ/PQ), DOE, SPC, and statistical analysis
• Knowledge of GD&T, tolerance analysis, and plastic part design considerations
• Familiarity with Lean manufacturing and continuous improvement methodologies

Professional Strengths

• Strong analytical and data‑driven problem‑solving skills
• Ability to lead complex projects and influence cross‑functional teams
• Excellent documentation and process standardisation practices
• Effective communicator with the ability to work across all levels of the organisation
• Passion for innovation, continuous improvement, and technical excellence

Ready to Make an Impact?

If you’re a subject matter expert in plastic injection moulding who thrives on solving complex challenges and driving manufacturing innovation, this is your opportunity to lead and shape the future of high‑performance manufacturing. Join a collaborative team where your expertise directly influence product quality, operational excellence, and next‑generation manufacturing capabilities.

Our Benefits

• Competitive Salary: $100,000 – $120,000
• 401(k) Retirement Plan with Company Match
• Comprehensive Medical, Dental, and Vision Insurance
• Paid Time Off and Company Holidays
• Access to Career Development and Networking Opportunities Across Marmon Holdings

Following receipt of a conditional offer of employment, candidates will be required to complete additional job‑related screening processes as permitted or required by applicable law.

We are an equal opportunity employer, and all applicants will be considered for employment without attention to their membership in any protected class.

If you require any reasonable accommodation to complete your application or any part of the recruiting process, please email your request to [e-mail], and please be sure to include the title and the location of the position for which you are applying.

Welcome to the biggest small business you’ll ever find.

Part of Berkshire Hathaway, Marmon is a global industrial organization made of 11 industry groups with 30K employees and $12 billion in annual revenue. As leaders in their respective industries, our 120+ companies thrive on an independent mindset and entrepreneurial spirit. At the same time, they benefit from being part of our industry groups—where they’re able to tap into the expertise and insights of other Marmon companies. While we’re all unique, we all share a common commitment to doing things that matter, leading at every level, and winning a better way.

Kate Suprenuk Appointed President of Marmon Rail