Process Engineer

Aegis Worldwide is partnered with a manufacturer in the Pendleton, IN area who is looking to add a Process Engineer to their team!

Must Haves:

Bachelor's degree in mechanical engineering (or related field)

3+ years of injection molding process engineering experience

PP and PC material knowledge

Job Responsibilities:

Support commissioning and validation of electric, hydraulic, and hybrid injection molding presses, robotics, downstream automation, dryers, chillers, and material handling systems.

Verify machine capability relative to material and mold requirements.

Optimize cycle times while protecting part performance and mold life.

Support mold trials, steel-safe modifications, and new tool launches.

Ensure molds are technically capable of operating within defined process windows.

Provide engineering guidance on wear components and mold preventive maintenance requirements.

Own molding-related process capability metrics (Cp/Cpk).

Implement and maintain SPC on critical process parameters and part characteristics.

Drive the transition from inspection-based quality control to process-controlled manufacturing.

Support investigations into scrap, quality holds, and customer complaints through rigorous data analysis.

Develop and validate robust process windows for PP, PC, and similar thermoplastics.

Define, document, and sustain golden process settings, including melt temperature and shear, injection velocity profiles, pack/hold pressure and time, cooling efficiency, and mold temperature control.

Apply material science principles—viscosity, shrinkage, crystallization behavior (PP), and thermal sensitivity (PC)—to process design and optimization.

Own process setup sheets, standard work, and controlled parameter limits to ensure repeatability.

Lead engineering analysis and resolution of complex molding defects such as flow hesitation, jetting, sinks, warp, blush, splay, burns, voids, and dimensional instability.

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