Molding and tooling engineer

This role is a hybrid position

This position is considered hybrid, allowing for a combination of remote work and in-office collaboration. Qualified applicants must live within commuting distance of our Boston, MA or Santa Barbara, CA office locations and should expect to be in office approximately 1-3 days per week. We will also consider remote based for a very qualified candidate that will come into the office once every 1-2 months for a week.

#LI-Hybrid

As the Molding and Tooling Engineer you will be responsible for delivery and validation of lead molding processing development and fabrication tooling designs for new product developments and secondary operations.  You will work with Mechanical Engineers, Supply Chain Management and Supply Quality Engineers to identify supply base vendors, fabrication technologies and create tooling designs to deliver high volume, high value consumer products with demanding cosmetic requirements. Using your extensive experience, you will investigate and implement industry best practices in molding process, tool design, construction and validation across a range of material and process requirements including plastic molding, metal part fabrication and decorative processes.  You will directly manage the tool design, development and qualification of molding and tooling designs required to deliver new product designs and support manufacturing capacity.

What You'll Do:

• Recommend material choices to meet mechanical, CMF (Color/Materials/Finish), Industrial Design and Operations requirements. Collaborate with Product Design, Industrial Design, and Mechanical Process Engineering teams to support product development.  

• Experience with setting up, running and troubleshooting injection molding machines preferred.  

• Ability to establish injection molding process window and cycle times. 

• Provide feedback to all teams on part and manufacturing concerns with design requirements. 

• Drive analytical modeling and analysis of tooling concepts and design through use of Plastic Flow simulation tools to provide upfront design feedback (Moldflow or MoldEx3D). 

• Create DFM (Design for Manufacturing) documents that include gating, parting lines, ejection locations, actions, thin steel conditions, design considerations to be provided to Mechanical engineers and suppliers. 

• Work directly with Quality organization to provide feedback on dimensional information,  FAI, Cp and Cpk. 

• Visit suppliers for onsite tool and part processing reviews, audit suppliers for plastic and metal parts and evaluate their capabilities, explore new manufacturing processes and materials and help standardize tooling practices and process controls across SONOS supplier base. 

• Manage multiple development programs at once.  

• Provide feedback into program schedules and risks. 

• Provide feedback to the GSM team on tool prices, lead times, production cycle times, tool cavitation and expected yields. 

• Mentor and develop mechanical engineers and junior tooling engineers in the area of plastic material selection and part design.

What You'll Need:

• Bachelor’s degree in Plastics or Polymer Engineering and Mold/Tool Design, Material Science and Engineering or related field

• 6 years experience in plastics part and tool design

Minimum Skills Required

• Experience with engineering grade plastic resins

• Experience with tight tolerance tooling and resolving out of spec issues.

• Proficient with GD&T, SPC, DOE and Six Sigma techniques

• Experience in plastic molding, metal casting, metal extrusion and metal stamping.

• Knowledge of plastic processes of 2-shot molding, IMD, IML, and insert molding.

• Knowledge of secondary processes such as machining and decorating (anodizing, plating, painting).

• Experience working with suppliers in Asia 

• Experience with CAD software (Pro/Engineer or Siemens NX solid modeling)

Research shows that candidates from underrepresented backgrounds often don't apply for roles if they don't meet all the criteria. If you don’t have 100% of the skills listed, we strongly encourage you to apply if interested.

Visa Sponsorship: Sonos is unable to sponsor or take over sponsorship of an employment visa for this role at this time. We ask that applicants be authorized to work for any US employer, both now and in the future.

At Sonos we consider a wide range of factors when determining compensation, which may lead  individual compensation to vary depending on job related qualifications, skills, and experience.  All full time employees are eligible for merit increases, discretionary bonuses, and equity.  Our job postings may span more than one career level and the base pay range may be modified in the future based on changing market conditions. The starting base pay for this role for all US candidates is between:

Please note that compensation details listed in US job postings reflect the base salary only, and do not include bonus, equity, or benefits.