Senior Mold Designer Jobs in Virginia (NOW HIRING)

As a part of the global industrial organization Marmon Holdings-which is backed by Berkshire Hathaway-you'll be doing things that matter, leading at every level, and winning a better way. We're committed to making a positive impact on the world, providing you with diverse learning and working opportunities, and fostering a culture where everyone's empowered to be their best.

MicroAire, who we are:

MicroAire Surgical Instruments, (Charlottesville, VA) is a wholly-owned subsidiary and one of five companies within the Medical Group of Marmon Holdings, a Berkshire Hathaway company. MicroAireis a mid-sized medical device solutions company with a 45-year legacy of quality and innovation. With well-recognized brands, the company is uniquely positioned as a leader in specialty markets, including minimally invasive medical devices and equipment for aesthetics/reconstruction, endoscopic soft tissue release, and orthopedic accessories.MicroAire designs, manufactures, and markets cutting-edge medical devices that empower surgeons to push the boundaries of surgical precision, delivering safe, efficient, and high-quality patient outcomes.

Position Summary

The Senior Manufacturing Engineer provides technical leadership for manufacturing operations supporting both existing products and new product introductions, with a strong emphasis on plastic injection molding processes, tooling, automation, and process optimization.

This role is responsible for developing, validating, optimizing, and sustaining molding processes and manufacturing systems that improve product quality, scalability, and operational performance. You'll collaborate cross-functionally, solve complex challenges, and help shape future manufacturing capabilities through innovation, scientific molding, and continuous improvement.

What You'll Do

• Lead Design for Manufacturing (DFM) and Design for Assembly (DFA) efforts focused on injection molded components, improving manufacturability, quality, and cost
• Develop, validate, and optimize injection molding processes, tooling, fixtures, automation systems, and secondary operations
• Establish and refine molding parameters (fill, pack, hold, cooling, resin drying, cycle time) using scientific molding principles
• Support mold design reviews, tooling qualification, first article inspection, and production readiness
• Troubleshoot molding defects such as flash, sink, short shots, warp, splay, burns, and dimensional variation
• Partner with tooling vendors, resin suppliers, and automation integrators to improve mold performance and uptime
• Evaluate and implement advanced manufacturing technologies including robotics, vision systems, and smart manufacturing solutions
• Lead new product introduction (NPI), process validation (IQ/OQ/PQ), DOE studies, and production launch readiness
• Develop scalable manufacturing strategies that support growth, efficiency, and long-term performance
• Author and maintain key documentation including PFMEA, control plans, work instructions, and process flows
• Lead engineering changes including tolerance analysis, resin evaluation, and mold/process improvements
• Serve as technical lead for complex manufacturing and quality challenges, driving root cause analysis and corrective actions
• Drive continuous improvement using Lean, Six Sigma, Kaizen, and scientific molding methodologies
• Mentor Manufacturing Engineers and Process Technicians, supporting technical growth and capability development
• Partner cross-functionally with Engineering, Operations, Quality, Supply Chain, and external stakeholders to achieve business objectives

What You Bring

Required:

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Plastics Engineering, or related field
• 5+ years of manufacturing engineering experience, ideally supporting injection molding or high-volume production environments
• Hands-on experience with injection molding process development, scientific molding, tooling validation, and troubleshooting

Preferred:

• Experience with automation, robotics, vision systems, or advanced manufacturing technologies
• Knowledge of engineered thermoplastics, resin behavior, and mold flow principles

Technical Expertise:

• Deep understanding of injection molding processes, tooling design, and process optimization
• Strong troubleshooting capability across molding defects, cycle optimization, and process stability
• Experience with validation (IQ/OQ/PQ), DOE, SPC, and statistical analysis
• Knowledge of GD&T, tolerance analysis, and plastic part design considerations
• Familiarity with Lean manufacturing and continuous improvement methodologies

Professional Strengths:

• Strong analytical and data-driven problem-solving skills
• Ability to lead complex projects and influence cross-functional teams
• Excellent documentation and process standardization practices
• Effective communicator with the ability to work across all levels of the organization
• Passion for innovation, continuous improvement, and technical excellence

Ready to Make an Impact?

If you're a subject matter expert in plastic injection molding who thrives on solving complex challenges and driving manufacturing innovation, this is your opportunity to lead and shape the future of high-performance manufacturing.

Join a collaborative team where your expertise will directly influence product quality, operational excellence, and next-generation manufacturing capabilities.

Following receipt of a conditional offer of employment, candidates will be required to complete additional job-related screening processes as permitted or required by applicable law.

We are an equal opportunity employer, and all applicants will be considered for employment without attention to their membership in any protected class. If you require any reasonable accommodation to complete your application or any part of the recruiting process, please email your request to careers@marmon.com, and please be sure to include the title and the location of the position for which you are applying.