Sr. Molding Engineer

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

Job summary

Ingersoll Rand is seeking a Sr. Process Engineer to develop, optimize, and sustain robust molding processes for liquid silicone rubber (LSR) and high‑consistency rubber (HCR) using injection, transfer, and compression molding.

You will partner with Tooling, Production, Quality, NPI, and Maintenance teams to ensure successful launches and stable manufacturing. The role requires 5+ years in silicone/rubber molding, strong DOE/SPC experience, and the ability to interpret GD&T and CAD drawings.

Qualifications

• Bachelor’s degree in Mechanical, Manufacturing, Materials, Plastics or Polymer Engineering.
• 5+ years of direct experience in silicone and/or rubber molding, with strong understanding of HCR molding, compression and transfer molding, cure cycles, post‑cure and material behavior.
• 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.

Responsibilities

• Process Development & Optimization: Develop, validate and optimize molding processes for HCR injection, compression and transfer molding.
• Training operators and technicians in molding best practices and process discipline.
• Tooling & Equipment Interaction: Partner with Tooling Engineer on gate/vent design for silicone and rubber molds, evaluate mold thermal management and production readiness.
• Cross‑Functional Collaboration: Work with NPI Engineering on feasibility reviews, new mold trials and qualification.

Skills

Process engineering

Molding

DOE

Cp/Cpk

Education

Bachelor’s degree in Mechanical, Manufacturing, Materials, Plastics or Polymer Engineering

Tools

SolidWorks

Mold flow analysis

Job description

Ingersoll Rand is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to age, ancestry, color, family or medical care leave, gender identity or expression, genetic information, marital status, medical condition, national origin, physical or mental disability, political affiliation, protected veteran status, race, religion, sex (including pregnancy), sexual orientation, or any other characteristic protected by applicable laws, regulations and ordinances.

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

Process Development & Optimization:

• Develop, validate and optimize molding processes for HCR injection, compression and transfer molding.
• Design for multi‑cavity, family molds and multi‑shot configurations.
• Apply scientific molding techniques to establish pack/hold strategies, cure and thermal control profiles, venting and flash prevention parameters.
• Perform process determination and DOE studies to improve capability (Cp/Cpk) and reduce variation.
• Establish and maintain standardized process parameter sheets, recipes and work instructions.

Troubleshooting & Technical Support:

• Provide daily technical support to address molding issues such as flash, short shots, cure variations, knit lines, voids, sticking and ejection problems, inconsistent shrink, durometer and dimensional stability.
• Lead structured root‑cause analysis (5 why, 8D, fishbone) and implement robust corrective and preventive actions.
• Train operators and technicians in molding best practices and process discipline.

Tooling & Equipment Interaction:

• Partner with Tooling Engineer on gate/vent design for silicone and rubber molds, cold‑runner or valve‑gate LSR systems, mold thermal management and vent maintenance, mold qualification and production readiness.
• Support maintenance to ensure presses, injection units, dosing systems and thermolators operate within validated performance parameters.
• Improve mold robustness, reduce tool wear and minimize flash‑related issues.
• Drive improvements in cycle‑time optimization, scrap and rework reduction, OEE, material usage and yield optimization.
• Participate in LEAN, Kaizen, 5S and efficiency projects.
• Use SPC, data analytics and process monitoring to identify and address instability.

Cross‑Functional Collaboration:

• Work with NPI Engineering on feasibility reviews, new mold trials and qualification.
• Support launch readiness and transfer to production.
• Assist Quoting/Estimating with cycle‑time projections, cavitation/tooling strategy input.
• Communicate clearly with Production and Quality teams on process changes, risks and improvement projects.

General Accountability:

• Cooperate and conduct professional conduct with coworkers, staff, and managers.
• Communicate effectively with employees and management, demonstrating corporate values: Quality, Accountability, Respect, Integrity, Open & honest communications, Teamwork.

Requirements

• Bachelor’s degree in Mechanical, Manufacturing, Materials, Plastics or Polymer Engineering.
• 5+ years of direct experience in silicone and/or rubber molding, with strong understanding of HCR molding, compression and transfer molding, cure cycles, post‑cure and material behavior.
• 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

Onsite.

Pay

The pay range for this role is $100–$125k.

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 employee stock grant, among other offerings.