DSB Technologies is seeking an Injection Molding Process Engineer for our Janesville, WI manufacturing facility. 

Role Summary:

The plastic Process Engineer is responsible for developing, optimizing, and sustaining the  injection molding manufacturing processes used to produce high-precision components. This role involves hands-on engineering in the areas of feedstock handling, injection molding, debinding, sintering, and secondary operations, with a strong focus on process capability, repeatability, and continuous improvement.

Key Responsibilities:

• Establish new and improve existing processes through Scientific Molding Philosophy for injection molded parts manufacturing line
• Define, control, and audit molding processes to improve overall manufacturing performance, eliminate or reduce waste and production costs, and improve quality
•  Recommend process, tooling, material, and equipment modifications
•  Implement standardized "Decoupled Molding II and III" procedures for new tool start-ups and daily production
•  Execute First Article Inspections and sample runs with new tooling to meet PPAP and PSO requirements, and establish tolerances for production
•  Program robots and sprue pickers used in injection molding
•  Perform periodic machine testing and validation such as injection speed linearity, dynamic check ring repeatability, load sensitivity, pressure response, and platen deflection testing
•  Conduct process testing including in-mold rheology tests, dynamic cavity imbalances testing, pressure loss studies, gate sealing, mold deflection testing, etc
•  Troubleshoot process problems, conduct root cause analysis, and identify corrective actions
•  Review and qualify process changes and make appropriate set-up sheet changes and standard operating procedures
•  Develop and coordinate training sessions for process technicians and operators based on decoupled molding techniques and rigorous mold try-out methods
•  Develop and optimize MIM processes from prototype through full-scale production, including injection molding, debinding, and sintering.
•  Troubleshoot process issues and drive root cause analysis for non-conformities.
• Perform DOE (Design of Experiments) and statistical process analysis to improve yields and reduce variability.
• Collaborate with R&D, Quality, Tooling, and Production teams to support new product introduction and existing product improvements.
• Design and validate robust process controls, documentation, and standard work instructions.
• Support tooling design reviews and provide feedback to ensure manufacturability and process consistency.
• Monitor and analyze key process metrics (e.g., Cp/Cpk, OEE, scrap rates) and implement corrective actions as needed.

 Technical Skills:

• Deep understanding of Injection molding principles, including material behavior, mold design, injection parameters, thermal profiles, and sintering science.
• Experience with process validation (IQ, OQ, PQ) and FMEA.
• Strong capability in statistical analysis and data interpretation (SPC, Minitab, JMP, etc.).

Soft Skills:

• Problem-solving and root cause analysis (5-Whys, Fishbone, A3).
• Clear and professional communication with cross-functional teams.
• Strong attention to detail and ability to manage multiple projects under tight timelines.
• Hands-on, collaborative, and continuous improvement mindset.

Tools & Software:

• Proficient in CAD (SolidWorks, AutoCAD), ERP systems, and Microsoft Office Suite.
• Experience with simulation software (e.g., Moldflow) is a plus.

Education & Experience Requirements:

• Bachelor’s Degree in Materials Science, Mechanical Engineering, Chemical Engineering, or a related field.
• 3–5 years of experience in injection molding (knowledge about Metal and ceramic injection molding, is a plus.).
• Experience in a regulated manufacturing environment (medical, automotive, aerospace, or defense) preferred.
• Certifications in Six Sigma, Lean Manufacturing, or similar process improvement frameworks are a strong plus.

Ideal Candidate Profile:

A successful Process Engineer is both analytically sharp and hands-on, capable of translating complex metallurgical principles into efficient, repeatable processes. They take ownership of production performance, proactively seek improvements, and thrive in a fast-paced, technical environment. They must be as comfortable on the production floor as they are in front of a computer running data analysis or presenting solutions to leadership

Experience competitive pay and benefits at DSB Technologies

• 3+ weeks PTO
• Affordable health insurance
• Free dental insurance with health insurance
• Company-paid life insurance
• 9 paid holidays
• Tuition reimbursement program
• 401(k) plan with company match