Body Systems Injection Molding Engineer

About the role

Own the full lifecycle of injection molded body‑system components — from tooling concept and mold design through process development, production launch, and ongoing quality assurance — for electric vehicle applications. Work on‑site in Troy, MI as a senior‑level contract engineer in a fast‑paced startup environment.

Responsibilities

• Be an integral part of an energetic team redefining electric vehicles with injection molded components at the heart of the body system.
• Review and approve mold designs, manage tooling builds with suppliers, and drive mold qualification (T1–T3 and beyond).
• Develop, validate, and document robust injection molding processes using scientific molding principles — establishing and locking process windows for pressure, temperature, fill rate, pack, hold, and cooling.
• Manage all aspects of injection molded components to meet program requirements including dimensional performance, functional sealing performance, cost, mass, cycle time, and manufacturability.
• Own component quality from mold qualification through production: lead PPAP submissions, develop control plans, drive root cause analysis on defects, and implement corrective actions to ensure zero‑escape quality.
• Collaborate with design, manufacturing, and supplier engineering teams to execute DFM reviews, mold flow analysis, and tolerance studies that eliminate risk early in development.

Requirements

• Bachelor’s Degree in Mechanical Engineering, Plastics Engineering, or related field from an ABET accredited university.
• 5+ years of hands‑on injection molding engineering experience spanning tooling design, process development, and production support for high‑volume plastic components.
• Senior‑level hires only.
• Contract position, on‑site in Troy, MI.

Skills

• Deep knowledge of injection mold tooling: cavity and core design, side actions, lifters, hot runner systems, cooling circuit layout, tool steel selection, and mold maintenance practices.
• Proficiency in scientific molding methodology, including systematic process development, DOE, and the use of SPC and process capability metrics to control part quality.
• Strong understanding of thermoplastic and thermoplastic elastomer materials (TPE, TPO, EPDM, PP, PA, PC/ABS) and how material properties affect shrinkage, warpage, sink, and functional performance.
• Demonstrated experience with quality systems and launch tools: APQP, PFMEA, control plans, PPAP, GD&T, MSA, and capability studies in a production injection molding environment.
• Familiarity with mold flow simulation software (Moldex3D, Autodesk Moldflow, or equivalent) and ability to interpret results to drive tooling and process decisions.
• Excellent communication and collaboration skills, with ability to manage multiple suppliers and cross‑functional priorities in a fast‑paced startup environment.