Senior Principal Engineer, Plastics Molding — Pharmaceutical Manufacturing & Medical Devices

AbbVie Inc.; Worcester (MA); Hybrid; USD 150,000 - 210,000; Full time

Job summary

AbbVie Inc. in North Chicago, IL seeks a Senior Principal Engineer to provide enterprise-level leadership for plastics molding across pharma manufacturing, devices, and biologics.

You will guide complex molding projects from concept through validation in a regulated environment. Responsibilities include directing injection/blow molding tech, equipment, tooling, and supplier management, with travel as needed.

Qualifications

• Bachelor’s degree in Mechanical Engineering, Plastics Engineering, Engineering, Science, or related field.
• 8–10 years of significant engineering/operational experience in regulated industries.
• 3+ years of plastic injection molding and/or blow molding design and process-support experience.
• Knowledge of molding equipment, plastics processes and resins, tooling, inspection procedures, SPC, and ISO/regulatory requirements.
• Experience with tooling/automation design; procurement; supplier management; FMEA, DOE, FAT, validation, metrology.

Responsibilities

• Lead medium- to large-sized molding projects from concept to qualification and validation.
• Develop injection- and blow-molding solutions meeting product quality, cost, and regulatory expectations.
• Provide direction on equipment, tooling, automation, resin selection, and process development.
• Communicate risks, status, and decisions to management; support supplier management.
• Lead or support tooling and automation design, procurement, qualification, and acceptance criteria.

Skills

Molding engineering

FMEA

DOE

SPC analysis

Manufacturing readiness

Education

Bachelors in Mechanical/Plastics Eng or related

Tools

SolidWorks

Creo/ProE

AutoCAD

Job description

Company Description

About AbbVie

AbbVie's mission is to discover and deliver innovative medicines and solutions that solve serious health issues today and address the medical challenges of tomorrow. We strive to have a remarkable impact on people's lives across several key therapeutic areas including immunology, oncology and neuroscience - and products and services in our Allergan Aesthetics portfolio. For more information about AbbVie, please visit us at www.abbvie.com. Follow @abbvie on LinkedIn, Facebook, Instagram, X and YouTube.

Job Description

Position Overview

Full-time | Hybrid

The Senior Principal Engineer, Plastics Molding provides enterprise-level technical leadership for plastic injection molding and blow molding technologies supporting pharmaceutical manufacturing, medical devices, biologics, healthcare, and closely related regulated products. This role leads complex engineering initiatives across the product and process life cycle, advancing robust, compliant, scalable molding solutions through close partnership with internal stakeholders and external suppliers.

Key Responsibilities

• Lead medium- to large-sized, complex molding engineering projects from concept and design through procurement, qualification, validation, and sustained support.
• Develop and implement technically sound injection- and blow-molding solutions that meet product, process, quality, cost, and regulatory expectations.
• Provide technical direction on equipment, tooling, automation, resin selection, process development, inspection strategy, and manufacturing readiness.
• Conduct risk assessments, manage life-cycle costs, and communicate technical recommendations, project status, and risk-based decisions to management.
• Support supplier selection, supplier performance, and technical issue resolution for molds, equipment, automation, and related services.

Technical and Functional Accountabilities

• Apply deep knowledge of plastics processes, resins, injection molding equipment, blow molding, tooling, and inspection procedures to optimize process capability and product quality.
• Plan and execute FMEAs, design of experiments (DOE), dimensional analysis, statistical process control (SPC) analysis, factory acceptance testing (FAT), equipment and process qualification, and validation activities.
• Translate design controls, quality-system expectations, regulatory requirements, and applicable ISO requirements into practical engineering deliverables and manufacturing controls.
• Lead or support tooling and automation design, procurement, qualification, and supplier management; evaluate technical proposals and acceptance criteria.
• Use metrology and dimensional data to investigate variation, establish process controls, and drive effective corrective technical actions.
• Maintain working familiarity with CNC equipment, wire EDM, surface finishes, grinders, hand tools, and 3D CAD platforms including SolidWorks, Creo/ProE, and AutoCAD.

Candidates are considered based on relevant qualifications, skills, and experience. The role welcomes a diverse range of backgrounds and perspectives consistent with applicable equal employment opportunity principles.

Leadership and Collaboration

• Serve as a recognized technical resource, providing clear, evidence-based guidance on molding technology, manufacturability, risk, quality, and life-cycle decisions.
• Partner effectively with cross-functional teams and external collaborators, including manufacturing, quality, engineering, procurement, suppliers, and service providers.
• Influence technical alignment across stakeholders, facilitate resolution of complex issues, and enable timely execution in a regulated operating environment.
• Communicate complex engineering concepts clearly to technical and non-technical audiences and advise management on options, tradeoffs, and recommendations.

This is a hybrid role based in North Chicago, Illinois. Work may include collaboration across office, manufacturing, supplier, and project environments.

Travel up to 40% may be required to support suppliers, equipment and tooling activities, factory acceptance testing, qualification, validation, and cross-functional project needs.

#LI-AL1

Qualifications

• Bachelor’s degree in Mechanical Engineering, Plastics Engineering, Engineering, Science, or a related field; equivalent technical experience may be considered.
• 8-10 years of significant engineering and/or operational experience, preferably in pharmaceutical manufacturing, medical devices, biologics, healthcare, or another closely related regulated industry.
• 3+ years of plastic injection molding and/or blow molding design and process-support experience.
• Demonstrated knowledge of molding equipment, plastics processes and resins, tooling, inspection procedures, SPC analysis, and applicable regulatory and ISO requirements.
• Demonstrated experience with tooling and automation design; procurement and qualification; supplier management; FMEA, DOE, dimensional analysis, FAT, validation, design controls, metrology, and quality systems.

Additional Information

• The compensation range described below is the range of possible base pay compensation that the Companybelieves ingood faith it will pay for this role at the timeof this posting based on the job grade for this position.Individualcompensation paid within this range will depend on many factors including geographic location, andwemayultimatelypaymore or less than the posted range. This range may bemodifiedin thefuture.

• We offer a comprehensive package of benefits including paid time off (vacation, holidays, sick),medical/dental/visioninsurance and 401(k) to eligibleemployees.

• This job is eligible toparticipatein our long-term incentiveprograms.

Note: No amount of payis considered to bewages or compensation until such amount is earned, vested, anddeterminable.The amount and availability of any bonus,commission, incentive, benefits, or any other form ofcompensation and benefitsthat are allocable to a particular employeeremainsin the Company's sole andabsolutediscretion unless and until paid andmaybemodifiedat the Company’s sole and absolute discretion, consistent withapplicable law.

AbbVie is an equal opportunity employer and is committed to operating with integrity, driving innovation, transforming lives and serving our community. Equal Opportunity Employer/Veterans/Disabled.

US & Puerto Rico only - to learn more, visit https://www.abbvie.com/join-us/equal-employment-opportunity-employer.html

US & Puerto Rico applicants seeking a reasonable accommodation, click here to learn more:

https://www.abbvie.com/join-us/reasonable-accommodations.html