About The 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 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
What We'll Give You In Return
Ready to make an impact
From developing game-changing air fryers to perfecting the art of coffee making, Versuni's purpose is turning houses into homes and we're calling on your talent to bring it to life. Join our global team of 6,000+ passionate individuals, work with world-class brands, and shape the future of home living. We're ready for you are you ready for us
