Principal Process Engineer (Injection Molding)

Principal Process Engineer – Injection Molding

Location: Libertyville, IL (Relocation assistance available for qualified candidates)

Travel Requirements: 20% travel, 1-2 weeks at a time.

Starting Comp: $145,000–$200,000/year + 10% Annual Bonus

Overview

We are seeking an experienced Principal Process Engineer to implement and oversee advanced injection molding processes supporting state-of-the-art tooling and medical device manufacturing for a key global customer. This role partners closely with customers and internal engineering, quality, and manufacturing teams to establish robust, validated, and highly controlled molding processes. This is a senior, hands-on role ideal for a process expert who understands scientific/decoupled molding methodologies, thrives in regulated medical device environments, and is comfortable working directly on the manufacturing floor while collaborating internationally.

Key Responsibilities

• Implement, control, and optimize advanced injection molding processes for medical device components.
• Establish and maintain stable processes using decoupled (scientific) molding methodologies, often aligned with RJG principles.
• Lead molding process validation activities, including IQ/OQ/PQ, and support validation documentation in compliance with medical device requirements.
• Oversee process execution on advanced injection molding equipment and support mold startups and process troubleshooting.
• Diagnose process issues, determine corrective actions, and drive continuous improvement initiatives.
• Collaborate with quality, tooling, and manufacturing teams to ensure process capability and compliance.
• Serve as a technical partner to a top-tier customer based in Denmark, including periodic international travel.
• Provide hands-on support on the shop floor and technical guidance to technicians and engineers.

Required Qualifications

• Bachelor’s degree in Engineering or a related technical discipline.
• Extensive experience in injection molding process engineering within a medical device manufacturing environment.
• Strong understanding of decoupled / scientific molding processes (RJG or equivalent methodologies).
• Proven experience in establishing and executing molding process validations.
• Ability and willingness to be hands-on in a manufacturing setting.
• Strong problem-solving, analytical, and communication skills.
• Willingness to travel internationally several times per year.