Mold Process Engineer, Automotive Division

Mold Process Engineer (Automotive Division)

Location: Rochester Hills, MI (Onsite)

Travel: Up to 30-40% (Global)

Relocation assistance available | Visa sponsorship not offered

Join our Transportation Industrial Solutions (TIS) team as a Mold Process Engineer and accelerate your career by owning mold tooling and process development that directly impacts product quality, cost, and launch success.

In this hands-on role, you'll work directly with new product teams to advise on robust design for manufacturability, lead end-to-end tooling initiatives (including supplier coordination and on-site qualifications), apply scientific molding and CAE techniques to reduce lead times and capital spend, and employ strong problem-solving skills to diagnose and resolve complex molding and tooling issues.

The global TIS Mold Engineering team delivers cutting-edge connector, sensing, and interconnect solutions to the global automotive, transportation, and industrial markets, supporting next-generation vehicles, electrification, and smart mobility applications. We partner closely with Mold Design, Operations, and Product Design to drive measurable improvements in division KPIs, thrive in a fast-paced global environment, and collaborate with peers, remote sites, and external suppliers to deliver production-ready molds on time and under budget.

As part of Molex and Koch Industries, we operate under Principle Based Management (PBM), empowering employees to think like entrepreneurs, create value, and grow their careers in a culture built on integrity, knowledge sharing, and continuous improvement.

• Lead new tooling and mold initiatives: manage quotes, DFM, concept/tool approvals, Moldflow CAE validation, and supplier coordination (remote and on-site) through tool qualifications.
• Own end-to-end mold development: define qualification criteria, develop and verify scientific molding processes, and drive launch readiness into operations.
• Optimize process parameters using cavity-pressure data and statistical methods (DOE); correlate CAE and measured part/process data to ensure robust, repeatable production windows.
• Manage project execution and documentation: track schedule, status, budget, and milestones; ensure complete, version-controlled records (estimates, CAE results, tooling plans, QC reports).
• Provide technical support and troubleshooting for equipment, tooling, and process issues; lead corrective actions with operations and suppliers, and transfer lessons learned across teams to drive continuous improvement.
• Drive measurable improvements in tooling cost, cycle time, scrap reduction, and on-time mold delivery against defined KPI targets.
• Collaborate with global manufacturing plants to ensure successful mold transitions and alignment with receiving site expectations.

• Minimum 5+ years of experience in injection molding, mold development, and tooling.
• Background in scientific molding principles with hands-on experience on molding machines and ancillary equipment.
• Experience in tooling systems and design for manufacturability (hot-runner, cooling/ejection, venting, mold materials) and preventative strategies to minimize adjustments and scrap.
• Proven troubleshooting and problem-solving ability to diagnose molding/tooling issues and drive improvements in quality, cost, and lead time.
• Experience with CAD/3-D modeling, basic CAE flow analysis, and familiarity with GD&T for reviewing product prints.
• Demonstrated end-to-end project ownership: define qualification criteria, drive launch readiness, and manage schedule, budget, and milestones.
• Communication and stakeholder management skills, including experience collaborating with global manufacturing sites, suppliers, and cross-functional teams (Product Design, Operations, Quality).

• Bachelor's degree in Mechanical, Materials, Chemical, Plastics Engineering, or related discipline.
• Six Sigma Green Belt (or higher) or equivalent structured problem-solving training.
• RJG Master Molder I/II, AIM, or equivalent scientific-molding certification with hands-on expertise in cavity-pressure control, setting process windows, data acquisition, and transfer of best-practice settings.
• Experience with insert molding and overmolding processes, particularly for automotive connector or electronic component applications.
• Practical experience with new tooling launches, supplier coordination, and on-site tool qualifications for transportation/automotive components.
• Proficient with CAE simulation tools (Moldflow, Moldex3D, Sigmasoft) and able to correlate simulation results with measured part and process data.
• Strong systems and CAD skills: ERP/PLM (SAP, Windchill/Teamcenter or similar), advanced Excel (pivot tables, formulas, VBA), and 3-D CAD (NX preferred).
• Experience working in a global, fast-paced manufacturing environment with shifting priorities.

As a Koch company, Molex is a leading supplier of connectors and interconnect components, driving innovation in electronics and supporting industries from automotive to health care and consumer to data communications. The thousands of innovators who work for Molex have made us a global electronics leader. Our experienced people, groundbreaking products and leading-edge technologies help us deliver a wider array of solutions to more markets than ever before.