Sr. Molding Engineer

Ingersoll Rand; Lincolnshire (IL); On-site; USD 100,000 - 125,000; Full time

Job summary

Ingersoll Rand is seeking a Sr. Process Engineer in Lincolnshire, IL to develop and optimize molding processes for liquid silicone rubber and high consistency rubber, driving capability and cycle time reductions across multiple work centers.

You will collaborate with Tooling, Production, Quality, NPI and Maintenance teams to qualify molds, validate equipment, and lead DOE/SPC based improvements while training operators on best practices.

Qualifications

• Bachelor's degree in Engineering required.
• 5+ years' experience in silicone or rubber molding.
• Experience with LSR or HCR molding preferred.

Responsibilities

• Develop, validate, and optimize LSR and HCR molding processes.
• Establish robust process parameters, including injection/fill profiles and cure cycles.
• Troubleshoot molding defects using root cause analysis and corrective actions.
• Partner with tooling and maintenance teams to qualify molds and improve designs.
• Drive continuous improvement for cycle time, scrap, OEE and material yield.
• Support NPI through mold trials, process qualification, and production launch.
• Develop documentation and train operators on best practices.
• Collaborate cross-functionally to meet quality, customer, and business goals.

Skills

LSR molding

HCR molding

Injection molding

Compression molding

Transfer molding

DOE

SPC

GD&T

Engineering drawings

CAD

Education

Bachelor's degree in Engineering

Tools

SolidWorks

Mold flow analysis

3D CAD

Job description

Job Title

Sr. Process Engineer

Location

Lincolnshire, IL

About Us

Imagine a company with technology leadership of over 160 years, yet it operates with the energy of a startup. Ingersoll Rand has dedicated itself to Making Life Better for its employees, customers, shareholders, and planets. We produce innovative and mission-critical flow creation and life science technologies - from compressors to precision handling of liquids, gasses, and powers - to increase industrial productivity, efficiency, and sustainability. Supported by over 80+ brands, our products are used in various end-markets including life sciences, food and beverage, clean energy, industrial manufacturing, infrastructure, and more. Across the globe, we're driving growth with an entrepreneurial spirit and ownership mindset. Learn more at irco.com and join us to own your future.

Job Overview

The Process Engineer is responsible for the development, optimization and sustaining robust molding processes for liquid silicone rubber (LSR) and high consistency rubber (HCR) utilizing injection, transfer and compression molding processes. The Process Engineer plays a key role in driving process capability, optimizing cycle times, reducing scrap, troubleshooting production issues and ensuring stable manufacturing performance across all molding work centers. The Process Engineer collaborates closely with the Tooling, Production, Quality, NPI and Maintenance teams to ensure successful product launches, consistent quality and efficient manufacturing processes.

Responsibilities

• Develop, validate, and optimize LSR and HCR molding processes (injection, compression, transfer) using scientific molding principles and DOE methodologies.
• Establish robust process parameters, including injection/fill profiles, pack/hold strategies, cure cycles, and thermal controls to improve capability (Cp/Cpk) and reduce variation.
• Troubleshoot complex molding defects (flash, short shots, voids, knit lines, shrinkage, dimensional variation, and cure issues) using structured root cause analysis and corrective actions.
• Partner with tooling and maintenance teams to qualify molds, optimize gate/vent designs, improve thermal management, and ensure validated equipment performance.
• Drive continuous improvement initiatives focused on cycle time reduction, scrap minimization, OEE improvement, material yield optimization, and Lean/Kaizen implementation.
• Support New Product Introduction (NPI) through feasibility assessments, mold trials, process qualification, production launch, and transition to manufacturing.
• Develop and maintain process documentation, standardized parameter sheets, work instructions, and SPC-based process monitoring while training operators and technicians on best practices.
• Collaborate cross-functionally with Engineering, Production, Quality, and Estimating teams to improve manufacturability, manage process changes, and ensure quality, customer, and business objectives are achieved.

Requirements

• Bachelor's degree in an Engineering (Mechanical, Manufacturing, Materials, Plastics, Polymer)
• 5+ years' direct experience in silicone and/or rubber molding

Competences

• Liquid Silicone Rubber (LSR) injection.
• High Consistency Rubber (HCR) molding.
• Compression and transfer molding.
• Cure cycles, post-cure and material behavior.
• Tool design elements (cavitation, gating, venting, steel types).
• Experience using DOE, SPC and statistical tools for process improvement.
• Strong ability to interpret engineering drawings, GD & T, CAD models, customer and regulatory specifications.
• Demonstrated success in troubleshooting complex molding issues.

Preferences

• Experience with SolidWorks or other 3D modelling software.
• Experience with mold flow analysis (or ability to interpret results).
• Background in medical, automotive, aerospace or industrial silicone components.
• Experience supporting APQP, PPAP and customer audits.
• Experience with automation, vision inspection and deflashing /trimming technologies.
• Background with adhesion/bonding techniques, multi-shot molding and over molding.
• RJG/Paulson certification or silicone-specific molding training.
• Familiarity with ISO13485 and clean room procedures would be beneficial.

Travel & Work Arrangements/Requirements

• Fully onsite based

Pay Range

The pay range for this role is $100,000-$125,000. The pay range considers a wide range of factors that include a candidate's skills; experience and training; licensure and certifications; and geographic location.

What We Offer

At Ingersoll Rand, we embrace a culture of personal ownership - taking responsibility for our company, our communities, and our environment, as well as our individual health and well-being. Our comprehensive benefits package is designed to empower you with the tools and support necessary to take charge of your health, ensuring that together, we can continue to make life better. Our range of benefits includes health care options like medical and prescription plans, dental and vision coverage, as well as wellness programs. Additionally, we provide life insurance, a robust 401(k) plan, paid time off, and even an employee stock grant, among other offerings. These benefits are our commitment to you, so you can be your best at work and beyond. Ingersoll Rand Inc. (NYSE:IR), driven by an entrepreneurial spirit and ownership mindset, is dedicated to helping make life better for our employees, customers and communities. Customers lean on us for our technology-driven excellence in mission-critical flow creation and industrial solutions across 40+ respected brands where our products and services excel in the most complex and harsh conditions. Our employees develop customers for life through their daily commitment to expertise, productivity and efficiency. For more information, visit www.IRCO.com.