Process Development Engineer Jobs in Dallas, TX (NOW HIRING)

Senior Process Engineer

Overview

The Senior Process Engineer is responsible for developing, optimizing, and troubleshooting injection molding processes to ensure efficient, high-quality, and cost-effective production. This role requires working with cross-functional teams to improve process stability, reduce waste, and drive continuous improvement initiatives. The engineer will play a key role in tooling qualifications, process standardization, and developing best practices in molding operations.

Responsibilities

• Develop, implement, and optimize injection molding processes to improve efficiency, quality, and cycle times.
• Troubleshoot and resolve molding defects, tooling issues, and process variations using root cause analysis techniques.
• Utilize scientific molding principles and process optimizations tools including Design of Experiments to establish capable and consistent molding processes.
• Assist with new production equipment installation and qualification, providing feedback on suitability, performance and reliability.
• Lead process development for tool qualifications and test runs supporting both new product introductions and capacity tooling.
• Work closely with tooling engineers, maintenance teams, and production staff to enhance mold performance and longevity.
• Standardize process documentation, including work instructions, SOPs, and process sheets.
• Implement continuous improvement projects focused on cycle time reduction, scrap reduction, and process efficiency.
• Research and recommend new molding technologies, automation, and auxiliary equipment to enhance production capabilities.
• Provide technical leadership and training to engineers, technicians, and production personnel.
• Ensure compliance with all quality standards and company policies.
• Actively represent the processing capability during mold design reviews and DFM evaluations to insure processing consideration are included in the tooling design cycle.
• Provide on-site support for tooling trials and evaluations at tooling vendors
• Recommend resins and additive packages to support product performance requirements and manufacturing needs while insuring all material-based safety protocols and PPE needs are understood and met.

Must Haves

• Bachelor's degree in Mechanical engineering, Plastics engineering, or a related field.
• 7+ years of experience in injection molding process development, tooling, and manufacturing with a focus on tight tolerance, precision injection molding.
• Formal Master Molder or similar training RJG, AIM, etc. a strong plus
• Strong understanding of polymer materials, mold construction, and processing parameters with a focus on engineering grade resins including PEI, PBT, and PC/ABS.
• Expertise in scientific molding techniques, mold flow analysis, and process validation methodologies.
• Hands-on experience with injection molding machines, robotics, and automation systems.
• Familiarity with lean manufacturing principles, Six Sigma methodologies (Green/Black Belt preferred), and SPC.
• Proficiency in troubleshooting molding defects such as flash, short shots, burns, warpage, and splay.
• Strong analytical, problem-solving, and project management skills.
• Demonstrated ability to make data-driven decisions using data analysis tools and techniques.
• Effective communication and teamwork abilities for cross-functional collaboration.

What We Offer

• Competitive base salary with performance-based bonus potential
• 4 weeks of PTO to relax and recharge
• Health, dental, and vision plans to support you and your family
• 401(k) retirement savings plan with employer match and planning resources
• A collaborative, team-based culture focused on innovation and quality
• Paid holidays and employee recognition programs
• Opportunities to work with advanced molding technologies and infrastructure systems
• STEM outreach and community engagement initiatives

US Conec will only employ those who are legally authorized to work in the United States. This is not a position for which sponsorship will be provided. Individuals with temporary visas such as E, F-1, H-1, H-2, L, B, J or TN or who need sponsorship for work authorization now or in the future, are not eligible for hire.