Sr. Molding Engineer

As a Sr. Molding Engineer, you will be responsible for the development, optimization, and maintenance of robust molding processes for liquid silicone rubber (LSR) and high consistency rubber (HCR). You will utilize injection, transfer, and compression molding processes to ensure stable manufacturing performance across all work centers. You will play a key role in driving process capability, optimizing cycle times, reducing scrap, troubleshooting production issues, and ensuring quality product launches.

• Develop, validate, and optimize molding processes for LSR injection molding, HCR injection, compression, and transfer molding.
• Apply scientific molding techniques to establish injection/fill profiles, pack/hold strategies, and cure and thermal control profiles.
• Perform process determination and DOE studies to improve process capability and reduce variation.
• Establish and maintain standardized process parameter sheets, recipes, and work instructions.
• Provide daily technical support to address molding issues such as flash, short shots, and cure variations.
• Lead structured root cause analysis and implement corrective actions.
• Train operators and technicians in molding best practices.
• Partner with Tooling Engineer on gate/vent design, cold runner or valve-gate LSR systems, and mold qualification.
• Drive improvements in cycle time, downtime, rework rates, material usage, and yield optimization.
• Participate in LEAN, Kaizen, 5S, and efficiency projects.
• Collaborate with NPI Engineering on feasibility reviews, new mold trials, and launch readiness.
• Communicate clearly with Production and Quality teams on process changes and improvement projects.

• Bachelors degree in Mechanical, Manufacturing, Materials, Plastics, or Polymer Engineering.
• 5+ years experience in silicone and/or rubber molding.
• Strong understanding of LSR injection, HCR molding, and compression and transfer molding.
• Proficiency in cure cycles, post-cure, material behavior, and tool design elements.
• Experience using DOE, SPC, and statistical tools for process improvement.
• Ability to interpret engineering drawings, GD&T, CAD models, and specifications.
• Proven success in troubleshooting complex molding issues.

• Experience with SolidWorks or other 3D modeling software.
• Experience with mold flow analysis.
• 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 overmolding.
• RJG/Paulson certification or silicone-specific molding training.
• Familiarity with ISO13485 and clean room procedures.

You will collaborate closely with the Tooling, Production, Quality, NPI, and Maintenance teams to ensure successful product launches and efficient manufacturing processes. The role requires active participation in LEAN, Kaizen, and 5S projects, and the use of SPC, data analytics, and process monitoring to identify and address instability. Dress code and specific hours are not specified, but the role demands adherence to safety and quality standards in a dynamic manufacturing environment.

This is a Permanent position based out of Buffalo Grove, IL.

The pay range for this position is $120000.00 - $130000.00/yr.

Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.

full benefits from client

This is a Permanent position based out of Buffalo Grove, IL.

This position is anticipated to close on Nov 6, 2026.

This is a fully onsite position in Buffalo Grove,IL.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email actalentaccommodation@actalentservices.com for other accommodation options.

San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.