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BH Job ID: 4604

Job title: Principal DFM Engineer

Location: Lincolnshire, IL

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.

The Principal DFM Engineer is responsible for driving design‑for‑manufacturability (DFM), process feasibility, and cost optimization for silicone and elastomer‑based products across the organization.

This role serves as a subject matter expert and strategic leader, owning the quoting process from a technical standpoint while establishing the manufacturing strategy from prototype through full‑scale production. Responsibilities include developing detailed cost models, defining tooling approaches, estimating validation requirements, and translating customer designs into robust, scalable manufacturing solutions.

The Principal DFM Engineer plays a critical role in guiding cross‑functional decision‑making and influencing customer outcomes, directly impacting business growth, margin performance, and long‑term capability development. While accountable for quotation and cost modeling, this position is primarily differentiated by its deep technical influence, shaping product design, tooling, and process strategies across the Elastomers Operation Unit. Additionally, this role advances best practices in LSR, HCR, and elastomer molding and extrusion technologies, particularly within regulated environments including Class II and Class III medical devices, while mentoring engineers and elevating organizational DFM capability.

• Lead comprehensive DFM evaluations for elastomer components and assemblies, providing actionable recommendations to optimize:
• Manufacturability and scalability
• Yield, robustness, and quality
• Cost efficiency and margin performance
• Regulatory and validation readiness
• Influence customer designs upstream through direct technical engagement and design reviews
• Identify critical‑to‑quality features, tolerance risks, and process limitations
• Define optimal manufacturing approaches across:
• HCR molding (compression, transfer)
• Extrusion and downstream operations
• Multi‑shot, overmolding, and bonded assemblies

• Serve as the technical owner of RFQs, developing detailed, transparent cost models for prototype through full production
• Translate DFM decisions into:
• Cycle time, cavitation, and capacity strategies
• Tooling concepts and lifecycle strategies (prototype vs production tooling)
• Labor, material utilization, scrap, and secondary operations
• Develop and present:
• NRE, validation (IQ/OQ/PQ), and lifecycle cost considerations
• Partner with Sales and Business Development in customer‑facing technical and commercial discussions
• Ensure alignment between technical assumptions, cost structure, and business objectives

• Define the end‑to‑end manufacturing strategy, including:
  • Prototyping approach and scale‑up pathway
  • Tooling phases and capital investment strategy
  • Automation and inspection strategies
  • Validation and qualification roadmap
• Define and evaluate tooling approaches:
  • Multi‑cavity vs. family molds
  • Cold runner systems, gating, venting, and parting line strategies
  • Steel selection, mold class, and lifecycle considerations
• Collaborate with Process Engineering, Tooling, Quality, and Operations to:
  • Validate manufacturability assumptions
  • Optimize cycle time, yield, and throughput
• Drive early‑stage decisions that impact long‑term operational efficiency, cost, and capacity

• Act as a technical bridge across:
  • Sales / Business Development
  • Engineering (Process, Tooling, Project)
  • Quality (validation, regulatory requirements)
  • Supply Chain (materials, MOQs, lead times)
• Lead technical reviews during RFQ, contract review, and NPI phases
• Ensure manufacturability, cost, and quality assumptions are clearly documented and transferred into execution
• Drive should‑cost modeling and cost‑out initiatives through improved mold designs, optimized cycle times, or new automation opportunities
• Analyze quote‑to‑actual performance and refine estimating accuracy
• Establish and standardize:
  • DFM guidelines
  • Costing methodologies
  • Quoting best practices and templates
• Identify and implement improvements in:
  • Tool design
  • Process efficiency
  • Material utilization
  • Automation strategies

• Mentor and develop engineers in DFM, elastomer processing, and cost engineering
• Serve as a subject matter expert (SME) for silicone and rubber processing technologies
• Support capability development and capital investment planning
• Contribute to long‑term technology roadmaps and strategic growth initiatives

• Bachelor’s degree in Engineering (Mechanical, Manufacturing, Materials, Polymer, or similar)
• 10+ years of experience in elastomer manufacturing, DFM or process engineering
• Deep expertise in:
  • Silicone (LSR, HCR) and rubber materials
  • Compression, transfer, and injection molding processes
  • Tooling design principles (cavitation, gating, venting, materials)
  • Cost modeling and estimating for elastomer components
• Validation requirements (IQ/OQ/PQ), APQP, PPAP
• Interpreting engineering drawings, GD&T, and 3D CAD models
• Regulatory and customer specifications (medical preferred)
• Experience working in cross‑functional and customer‑facing roles
• Proficiency with CAD tools (e.g., SolidWorks)

• Experience in medical device manufacturing (Class II / Class III)
• Experience in technical quoting and cost modeling
• Experience with:
  • Mold flow analysis and interpretation
  • Automation and high‑volume manufacturing systems
  • Multi‑material molding (overmolding, bonding, insert molding)
  • Experience in CDMO environment
  • Six Sigma or Lean Manufacturing certification
  • Strong technical and commercial acumen
  • Advanced problem‑solving and analytical skills
  • Ability to influence internal and external stakeholders
  • Excellent communication with both technical and non‑technical stakeholders
  • High level of ownership, accountability, decision‑making authority
  • Strategic mindset with attention to detail

• Fully site based

The pay range for this role is $100-$150k, excluding incentive opportunities. The pay range takes into account a wide range of factors that are considered in making compensation decisions including, but not limited to, skills; experience and training; licensure and certifications; and geographic location. Hired applicant will be eligible to receive (discretionary/nondiscretionary) annual bonuses and incentive compensation.

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.