Sr. Tooling Engineer, Plastic Injection Molding (Starlink)

Responsibilities

• Lead the development of new plastic injection tooling projects to meet a wide range of product performance and cosmetic requirements
• Lead and refine the design for manufacturing process by collaborating with supply management, product design, industrial design, and manufacturing engineering groups on material selection, design feasibility, and aesthetics of new plastic part and tooling designs
• Research and identify new materials, manufacturing technologies, and finish options
• Inform estimations of prototype and production manufacturing costs - tooling, secondary assembly, secondary finishing, and piece part
• Participate in supplier audits and final supplier selection
• Write prototype/development tooling request for quotes (RFQs)
• Publish and maintain a live master tooling schedule
• Conduct final approval for tooling design by performing DFM with supplier, including reviewing draft, gating strategy, Moldflow, and Mold Warp analysis
• Review and approve prototype/development tool designs, and tooling maintenance procedures
• Track suppliers' weekly build progress while participating in T1 samples
• Conduct final approval for releasing tooling to production teams by assessing part quality at tooling trials. Includes generating first article inspection (FAI) reports, Production Part Approval Process (PPAP) reports to ensure parts meet drawing and design specifications
• Decide corrective actions and direct tooling teams to perform tooling modifications when parts do not conform to design specifications

Requirements

• Bachelor’s degree in mechanical, materials engineering or other engineering discipline; OR 10+ years of professional experience engineering injection mold tools in lieu of a degree
• 5+ years of professional experience in direct hands-on injection mold design and/or injection mold construction
• 10+ years of experience in direct hands-on injection mold design and/or injection mold construction
• Strong to expert-level 3D CAD skills, including advanced surfacing and large assemblies Siemens NX fluency or must be able to learn and adopt it quickly as it will be the design package used
• Knowledge and experience in scientific molding/RJG molding
• Strong experience in setting up and performing detailed mold simulations (Autodesk Moldflow)

Preferred Skills And Experience

• Detail understanding of plastics molding-related process variables and their impact on throughput, quality, and yield rate
• Expert-level 3D CAD skills, including advanced surfacing and large assemblies Siemens NX fluency or must be able to learn and adopt it quickly as it will be the design package used
• Knowledge and experience in scientific molding/RJG molding
• Strong experience in setting up and performing detailed mold simulations (Autodesk Moldflow)

Basic Qualifications

• Bachelor’s degree in mechanical, materials engineering or other engineering discipline; OR 10+ years of professional experience engineering injection mold tools in lieu of a degree
• 5+ years of professional experience in direct hands-on injection mold design and/or injection mold construction

Additional Requirements

• Willingness to travel to other SpaceX sites and/or vendors for extended periods of time (~ 50% of the time)
• Standing and/or walking for long periods of time
• Willingness to work long hours and weekends as necessary to accommodate manufacturing and test campaigns