Lead Design for Manufacturing (DFM) and Design for Assembly (DFA) efforts focused on injection molded components, improving manufacturability, quality, and cost
Develop, validate, and optimize injection molding processes, tooling, fixtures, automation systems, and secondary operations
Establish and refine molding parameters (fill, pack, hold, cooling, resin drying, cycle time) using scientific molding principles
Support mold design reviews, tooling qualification, first article inspection, and production readiness
Troubleshoot molding defects such as flash, sink, short shots, warp, splay, burns, and dimensional variation
Partner with tooling vendors, resin suppliers, and automation integrators to improve mold performance and uptime
Evaluate and implement advanced manufacturing technologies including robotics, vision systems, and smart manufacturing solutions
Lead new product introduction (NPI), process validation (IQ/OQ/PQ), DOE studies, and production launch readiness
Develop scalable manufacturing strategies that support growth, efficiency, and long-term performance
Author and maintain key documentation including PFMEA, control plans, work instructions, and process flows
Lead engineering changes including tolerance analysis, resin evaluation, and mold/process improvements
Serve as technical lead for complex manufacturing and quality challenges, driving root cause analysis and corrective actions
Drive continuous improvement using Lean, Six Sigma, Kaizen, and scientific molding methodologies
Mentor Manufacturing Engineers and Process Technicians, supporting technical growth and capability development
Partner cross-functionally with Engineering, Operations, Quality, Supply Chain, and external stakeholders to achieve business objectives
What You Bring
Required:
Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Plastics Engineering, or related field
5+ years of manufacturing engineering experience, ideally supporting injection molding or high-volume production environments
Hands-on experience with injection molding process development, scientific molding, tooling validation, and troubleshooting
Preferred:
Experience with automation, robotics, vision systems, or advanced manufacturing technologies
Knowledge of engineered thermoplastics, resin behavior, and mold flow principles
Technical Expertise:
Deep understanding of injection molding processes, tooling design, and process optimization
Strong troubleshooting capability across molding defects, cycle optimization, and process stability
Experience with validation (IQ/OQ/PQ), DOE, SPC, and statistical analysis
Knowledge of GD&T, tolerance analysis, and plastic part design considerations
Familiarity with Lean manufacturing and continuous improvement methodologies
Professional Strengths:
Strong analytical and data-driven problem-solving skills
Ability to lead complex projects and influence cross-functional teams
Excellent documentation and process standardization practices
Effective communicator with the ability to work across all levels of the organization
Passion for innovation, continuo
Benefits
Vision insurance
Additional Information
MicroAire Surgical Instruments LLC
As a part of the global industrial organization Marmon Holdings-which is backed by Berkshire Hathaway- you'll be doing things that matter, leading at every level, and winning a better way. We're committed to making a positive impact on the world, providing you with diverse learning and working opportunities, and fostering a culture where everyone's empowered to be their best.
MicroAire, who we are:
MicroAire Surgical Instruments , (Charlottesville, VA) is a wholly-owned subsidiary and one of five companies within the Medical Group of Marmon Holdings, a Berkshire Hathaway company. MicroAire is a mid-sized medical device solutions company with a 45-year legacy of quality and innovation. With well-recognized brands, the company is uniquely positioned as a leader in specialty markets, including minimally invasive medical devices and equipment for aesthetics/reconstruction, endoscopic soft tissue release, and orthopedic accessories. MicroAire designs, manufactures, and markets cutting-edge medical devices that empower surgeons to push the boundaries of surgical precision, delivering safe, efficient, and high-quality patient outcomes.
Position Summary
The Senior Manufacturing Engineer provides technical leadership for manufacturing operations supporting both existing products and new product introductions, with a strong emphasis on plastic injection molding processes, tooling, automation, and process optimization.
This role is responsible for developing, validating, optimizing, and sustaining molding processes and manufacturing systems that improve product quality, scalability, and operational performance. You'll collaborate cross-functionally, solve complex challenges, and help shape future manufacturing capabilities through innovation, scientific molding, and continuous improvement.
Marmon · Charlottesville, VA