About this role:
Are you an expert enthusiastic about improving and standardizing manufacturing processes, using new technologies to make production faster, more cost-effective Join us together for new product launches and helping review and improve tools and designs with other teams!
The Senior Plastic Injection Engineer is a technical expert responsible for leading the development, validation, and industrialisation of complex plastic components, with a strong focus on In-Mold Assembly (IMA) and advanced moulding technologies. This role drives product design decisions, optimises toolability, manages suppliers, and leverages deep tooling knowledge to ensure world-class quality, cost, and delivery performance.
The impact you'll make:
Technical Leadership & DFM Influence
- Provide senior-level DFM/DFX guidance for complex plastic components.
- Lead early feasibility studies for IMA concepts, multi-component assemblies, 2K/3K and hybrid moulding processes.
- Recommend optimal parting lines, gate strategy, draft angles, inserts, and tolerance stack-ups.
- Drive manufacturability with minimal assembly steps.
Advanced Tooling Strategy & Development
- Lead tooling concept creation for IMA tools including mechanisms, slides, lifters, automation interface, and cavity layout.
- Approve detailed mould designs with focus on precision, longevity, and cycle efficiency.
- Use mouldflow analysis to predict warpage and fill behaviour.
- Drive tooling FAT/SAT and T0/T1/Tn trials.
Supplier Management & Toolmaker Oversight
- Engage with global toolmakers to ensure quality and cost competitiveness.
- Evaluate toolmaker capability, machining precision, and IMA competency.
- Provide on-site support during tool assembly and troubleshooting.
- Lead technical negotiations for tooling design and cost.
In-Mold Assembly Expertise
- Engineer IMA solutions: snap-fit assembly, inserts, in-mould fastening, welding, clipping, and overmolding.
- Collaborate with automation teams for robotic integration.
- Establish IMA process windows and inspection criteria.
Cost Engineering & Optimisation
- Review tooling quotations and benchmark supplier cost structures.
- Identify cost reduction opportunities through design and tooling optimisation.
- Influence design to minimise unnecessary tooling complexity.
Molding Process Development & Validation
- Lead DOE, optimisation, and capability studies for IMA tools.
- Troubleshoot complex defects including warpage, sink, flash, IMA misalignment, and assembly failure.
- Ensure Cpk/Cp capability for critical features.
Documentation & Governance
- Maintain DFM reports, tool reviews, flow analysis, trial reports, and progress trackers.
- Ensure compliance with engineering standards and quality systems.
The skills and knowledge you'll bring:
Degree/Diploma in Mechanical, Plastics, or Manufacturing Engineering.
Minimum 10 years experience in injection molding, tooling, or toolmaking.
Proven expertise in IMA and complex automation-integrated tooling.
Strong grounding in CNC machining, EDM, tool steel selection, and maintenance.
Proficient in CAD and mould simulation software.
Strong GD&T, tolerance, and metrology knowledge.
Experience with global suppliers and high-volume manufacturing.
Excellent communication and leadership skills.
Core Competencies
- Expert DFM/DFX
- Deep mould design & toolmaking knowledge
- IMA process leadership
- Supplier management & negotiation
- Advanced problem solving (8D, DMAIC)
- Strong documentation
- Project leadership across NPI and Mass Production
