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The Plastics Engineer – Injection Molding Process & Flow Simulation (PE) is responsible for performing mold flow simulations on new injection-molded part designs to proactively identify and mitigate potential manufacturing issues that could impact quoted cycle time, product quality, or profit margins. The PE also conducts flow simulations on existing injection-molded products as part of continuous improvement and problem-solving projects. The PE will collaborate closely with cross-functional internal engineering teams at Prudent American and play a critical role in validating and optimizing injection-molded components and tooling.

DUTIES AND RESPONSIBILITIES

• Perform mold flow simulations using Moldex3D to analyze and optimize part design, gate locations, cooling systems, vent locations, windage corrections, cycle times etc.
• Collaborate with product design and tool design teams to ensure manufacturability and moldability of plastic parts.
• Support tooling development from concept through production, including tool design reviews and trial evaluations.
• Develop and optimize and document, Robust injection molding processes to ensure quality, efficiency, and repeatability in production, using cavity pressure and/or temperature monitoring systems where available.
• Analyze process data and conduct root cause analysis for molding issues such as warpage, short shots, flash, sink marks, or flow lines. Make tool windage recommendations which counteract warpage and eliminate the need for shrink fixturing parts.
• Work with suppliers and internal teams to validate tooling and ensure alignment with project requirements and timelines.
• Recommend material selection based on performance requirements, moldability, and cost.
• Create and maintain technical documentation, including process setup sheets, DOE reports, and simulation results.
• Other tasks as assigned by the Director of Engineering.

QUALIFICATIONS

• Bachelor’s degree in Plastics Engineering, Polymer Science, Mechanical Engineering, preferred, and/or at least ten years of quality experience with documented results.
• Minimum 5 years of experience in injection molding process development and flow simulation.
• Hands-on experience with Moldex3D is highly preferred; experience with other flow simulation software (e.g., Autodesk Moldflow) is acceptable.
• Strong understanding of thermoplastics materials, mold design principles and scientific molding process development.
• Knowledge of scientific molding techniques, use of cavity pressure sensors, in mold thermocouples and data acquisition systems. RJG Inc. Master Molder training and systems knowledge, preferred.
• Familiarity with GD&T, DFM, and DFA practices.
• Proven problem-solving skills and ability to lead technical discussions with cross-functional teams.
• Excellent communication skills and attention to detail.
• Experience with multi-cavity molds, standard and valve gated hot runner systems, and complex core pull sequencing, preferred.
• Experience working with contract manufacturers domestic and oversea tool shops, preferred.
• Firearms design, manufacturing and assembly experience, preferred.

WORKING CONDITIONS

• Work is performed in an operational production environment, with split time spent in a typical office environment.
• Travel may be required to other company locations, customer sites, supplier facilities, or tooling vendors.

PHYSICAL REQUIREMENTS

• Prolonged periods of sitting at a desk and working on a computer.
• Walking and standing on production floor periodically.
• Occasionally lifting, up to 25 pounds at a time.

DIRECT REPORTS

Not Applicable.

Export Control Compliance Notice

This position may involve access to technology or software source code subject to U.S. export control laws (ITAR/EAR). Employment is contingent on verifying U.S. Person status or obtaining any necessary export license/confirming the availability of a license exception. Applicants must provide information for export control screening, which will be reviewed for compliance. Prudent Holdings may elect not to pursue a license or exception and may decline to proceed with an applicant on that basis.