Senior Project Engineers, Simulation/CAE – Injection Molding

The Madison Group | Plastic Consulting; Madison (WI); On-site; USD 90,000 - 130,000; Full time

Job summary

The Madison Group | Plastic Consulting is seeking a Senior Project Engineer focused on plastics processing and injection molding simulation. The candidate will evaluate manufacturability of plastic part designs using Moldflow and provide actionable recommendations to improve cost and performance.

Ideal applicants have elastics in plastics engineering, strong communication skills, and experience leading project management and marketing content creation for customer outreach.

Qualifications

• BS/MS degree in Mechanical/Polymer/Chemical/MSE or related discipline from an accredited university.
• Demonstrated history of developing customer relationships.
• Excellent verbal and written communication skills, with the ability to articulate complex findings to technical and non‑technical audiences.
• 2+ years of project management experience, including proposal development and execution.
• Hands-on experience with Autodesk Moldflow Insight or equivalent.

Responsibilities

• Perform advanced injection molding simulations to evaluate manufacturability of plastic part designs.
• Lead generation of marketing materials to assist in customer outreach activities.
• Communicate solutions and problem-solving approaches to clients with minimal supervision.
• Manage multiple projects concurrently and coordinate with clients on outcomes.

Education

BS/MS degree in Mechanical Engineering, Polymer Engineering, Chemical Engineering, Materials Science and Engineering or related discipline

Tools

Autodesk Moldflow Insight

Python

Job description

The Madison Group has an opening for a Senior Project Engineer, with an emphasis on plastics processing and injection molding simulation. We are seeking a candidate with industry experience in the field of plastics engineering, with previous roles focused on design or manufacturing of plastic components.

• This position is a customer-facing, growth-oriented role, where the individual is responsible for strengthening customer relationships and evaluating the growth and development of services to better serve our customers.
• Perform advanced injection molding simulations, using Autodesk Moldflow Insight, to evaluate the manufacturability of their plastic part designs, and offer solutions to help achieve the customer’s objective. A successful candidate will be able to offer insight to customers on how the manufacturing process may be influencing the plastic part performance and cost.
• In addition to running simulations, the role responsibilities will require contributing and leading generation of marketing material to assist in customer outreach activities.
• The individual must be resourceful, capable of researching and learning, and be able to solve problems and communicate solutions with minimal supervision. Communication in this position requires the capability of expressing complex problems in a simple manner to both a technical and non-technical audience. The engineer will also perform project management tasks and communicate with clients. This position requires a dynamic individual who can manage multiple projects simultaneously.
• This position requires leadership and execution of multiple challenging tasks both related to project execution and business development. The individual is expected to have the ability to perform these tasks with minimal guidance.

The Madison Group has an opening for a Senior Project Engineer, with an emphasis on plastics processing and injection molding simulation. We are seeking a candidate with industry experience in the field of plastics engineering, with previous roles focused on design or manufacturing of plastic components.

• This position is a customer-facing, growth-oriented role, where the individual is responsible for strengthening customer relationships and evaluating the growth and development of services to better serve our customers.

• Perform advanced injection molding simulations, using Autodesk Moldflow Insight, to evaluate the manufacturability of their plastic part designs, and offer solutions to help achieve the customer’s objective. A successful candidate will be able to offer insight to customers on how the manufacturing process may be influencing the plastic part performance and cost.

• In addition to running simulations, the role responsibilities will require contributing and leading generation of marketing material to assist in customer outreach activities.

• The individual must be resourceful, capable of researching and learning, and be able to solve problems and communicate solutions with minimal supervision. Communication in this position requires the capability of expressing complex problems in a simple manner to both a technical and non-technical audience. The engineer will also perform project management tasks and communicate with clients. This position requires a dynamic individual who can manage multiple projects simultaneously.

• This position requires leadership and execution of multiple challenging tasks both related to project execution and business development. The individual is expected to have the ability to perform these tasks with minimal guidance.

QUALIFICATIONS:

• BS/MS degree in Mechanical Engineering, Polymer Engineering, Chemical Engineering, Materials Science and Engineering or related discipline from an accredited university.
• 5+ years of practical experience in the field of plastics engineering.
• 3+ years hands on experience with injection molding preferred.
• In-depth understanding of injection mold design and manufacturing constraints.
• Demonstrated history of developing customer relationships.
• Experience with plastics joining and assembly techniques desirable. (Welding, Adhesives, and Fasteners)
• 2+ years of project management experience, including proposal development, project execution, and
• Demonstrates ability to complete assignments, meeting quality and time-oriented objectives.
• Hands-on experience with Autodesk Moldflow Insight or Equivalent Package is required.
• Excellent verbal and written communication skills, with the ability to articulate complex technical findings to both engineering and executive/non-technical audiences.

PREFERRED TECHNICAL ABILITIES:

• In addition to a strong injection molding background, experience with LSR molding, thermoforming, extrusion, compression molding, or additive manufacturing is desirable.
• Preferred certified Autodesk Moldflow Insight Analyst.
• Experience developing code using Python.
• Experience utilizing Statistical Analysis Techniques to understand manufacturing issues. (Minitab, DOE Set-up and analysis, short run manufacturing SPC).
• Structural FEA experience.
• Working knowledge of CRM platforms (e.g, Salesforce, Hubspot).
• Prior experience generating technical marketing content (case studies, white papers, technical presentations).

Company Description

The Madison Group | Plastic Consulting is a specialized engineering firm focused on the full lifecycle of plastic products, from concept through commercialization. Since 1993, the organization has offered integrated services such as design and development, manufacturing support, and material and product testing. With deep expertise in failure analysis and root cause analysis, the team helps clients proactively identify and avoid common design and manufacturing issues. Services include injection molding simulation, process reviews, on-site troubleshooting, and quality support, including litigation support. The Madison Group tailors its approach to each client’s technical needs and project schedule to help ensure successful outcomes for plastic products.