Extrusion Engineer Jobs in Wisconsin (NOW HIRING)

Up to $90,000 Base Salary • Kohler, WI Area • 100% Onsite (Direct Leadership Track)

EXPERIENCE DEPTH: 3+ years of dedicated success designing and engineering custom profile, co-extrusion, and tri-extrusion tooling from scratch.

PROCESSING ACUMEN: A minimum of 3 years of hands-on extrusion processing experience, giving you a deep mechanical understanding of how die designs affect melt streams, plastic flow, and physical part properties.

DESIGN SOFTWARE: Active proficiency with Mastercam and Fusion 360 to generate precise 3D data models, complex die geometries, and streamlined tooling parameters.

TECHNICAL MASTERY: Strong background in practical, hands-on tool tuning, adjustment, and calibration troubleshooting to achieve 100% part conformance.

GROWTH TRACK: Strategic role designed with a direct, structured runway to a Department Head/Leadership position to build and manage your own team over time.

COMPENSATION: Up to $90,000 baseline starting salary (scaling with technical depth) + premium corporate benefits package + exceptional work-life flexibility.

LOCATION: Kohler, WI area (100% onsite advanced production facility; must reside within a 45-minute daily commuting radius).

COMPLIANCE: United States Citizens or Green Card holders only.

This is an opportunity to join a thriving, ISO-certified custom plastics manufacturing leader that designs and engineers high-performance extrusion products for a highly diversified, resilient global customer base. Operating with complete economic stability and continuous year-over-year growth, this organization heavily and transparently reinvests its profits directly back into the facility. They foster a fiercely supportive, employee-friendly environment, resulting in an astounding average staff tenure of 20 years.

This lead-track position is engineered for a specialized tooling professional who wants to escape rigid corporate politics, bureaucratic red tape, and unpredictable mass-layoff cycles. Taking technical ownership of complex, multi-polymer tool development, you will solve engaging flow and calibration puzzles using current, cutting-edge software and production equipment. Bridging the gap between engineering blueprints and live shop-floor physics, you will work closely with internal toolmakers, setup technicians, and operators to optimize tooling assets from initial concept design through development and deployment. It is the ideal setup for a proactive, team-oriented communicator seeking unmatched job security, modern infrastructure, and a clear path toward professional department leadership.

• Die Geometry Engineering: Engineering custom plastic extrusion tooling and complex die geometries for specialized profile extrusion, co-extrusion, and tri-extrusion applications.
• Asset Lifecycle Management: Directing and managing the full lifecycle of tooling assets—from initial concept design and building to physical modification, deployment, and ongoing maintenance.
• Melt Stream Optimization: Partnering directly with production floor teams to troubleshoot complex processing variables on active lines, optimize polymer flow, and improve throughput efficiencies.
• Cross-Functional Technical Guidance: Providing high-level technical guidance, documentation, and hands-on assistance to machine operators, setup technicians, and internal toolmakers.
• Developmental Tool Tuning: Adjusting, tuning, and optimizing extrusion tooling and calibration components during development phases to ensure absolute part compliance to precise client dimensions.

• Custom Tooling Pedigree: 3 or more years of dedicated professional experience designing and developing complex multi-polymer profile extrusion dies from a blank page.
• Shop Floor Fluency: A collaborative, hands-on engineering mindset that values real-world feedback from the machinery, allowing you to easily interface with engineering and manufacturing grids.
• Analytical Problem Solving: Sharp critical-thinking skills to evaluate physical part defects (like surge, warp, or uneven wall thickness) and reverse-engineer the exact tooling or process adjustments required to fix them.
• Employment Reliability: A rock-solid, dependable work history that demonstrates career longevity and multi-year commitments at prior employers; frequent job-hopping every two years will not be evaluated.

Please apply here or at impactsolutions.com/opportunities where you can see and apply for any of our open positions.