Aegis Worldwide

Process Engineer

1st shift

$90,000-125,000

Position Summary:

Aegis Worldwide is partnered with a manufacturer in the Pendleton, IN area who is looking to add a Process Engineer to their team!

Must Haves:

• Bachelor's degree in mechanical engineering (or related field)
• 3+ years of injection molding process engineering experience
• PP and PC material knowledge

Job Responsibilities:

• Support commissioning and validation of electric, hydraulic, and hybrid injection molding presses, robotics, downstream automation, dryers, chillers, and material handling systems.
• Verify machine capability relative to material and mold requirements.
• Optimize cycle times while protecting part performance and mold life.
• Support mold trials, steel-safe modifications, and new tool launches.
• Ensure molds are technically capable of operating within defined process windows.
• Provide engineering guidance on wear components and mold preventive maintenance requirements.
• Own molding-related process capability metrics (Cp/Cpk).
• Implement and maintain SPC on critical process parameters and part characteristics.
• Drive the transition from inspection-based quality control to process-controlled manufacturing.
• Support investigations into scrap, quality holds, and customer complaints through rigorous data analysis.
• Develop and validate robust process windows for PP, PC, and similar thermoplastics.
• Define, document, and sustain golden process settings, including melt temperature and shear, injection velocity profiles, pack/hold pressure and time, cooling efficiency, and mold temperature control.
• Apply material science principles—viscosity, shrinkage, crystallization behavior (PP), and thermal sensitivity (PC)—to process design and optimization.
• Own process setup sheets, standard work, and controlled parameter limits to ensure repeatability.
• Lead engineering analysis and resolution of complex molding defects such as flow hesitation, jetting, sinks, warp, blush, splay, burns, voids, and dimensional instability.