Plastics Process Engineer - AR\/VR Labs

As a Plastics Process Engineer on the AR/VR Labs team, you will run experiments, design tooling, choose materials in the manufacture of plastic parts to help us develop the future of augmented and virtual reality devices. Hands-on experience running injection/compression/extrusion presses, proficiency designing molding tools, and the theoretical underpinning of a formal education in plastics or chemistry will prepare you well for this role involving a mix of high-level design and hands-on process development in our Menlo Park lab. Engaging with product designers and research scientists, you will outline the development work necessary to enable new technologies, gather the needed materials, and deliver solutions supported by empirical data gathered through your own trials. You must be organized and self-directed to work well on this small team of subject matter experts - we will count on you for your technical leadership in your field and expect you to be able to provide an ambitious vision for process development within your domain.


  • Provide specific and accurate guidance, driven by both theory and experience, to design engineers in order to improve the manufacturability of molded parts, and to process engineers to refine equipment selection, tooling design, and process parameters for molding operations
  • Ownership of prototype molding at an internal lab on campus, including tool design (2D/3D), supervision of tool manufacture by in-house machinists, selection of process parameters, first article validation, and outgoing quality control
  • Apply theory and experience to run process trials (hands on) that stretch existing molding techniques or enable completely new ones in order to support product enabling technologies under development
  • Occasional (2-3 times annually) travel to contract manufacturers in Asia to oversee trials, address defects through process adjustments, and grow supplier capabilities to accommodate future business needs
  • Push boundaries and test limits to create innovative proof of concepts, design testing systems, design and implement shop/lab equipment and support a diverse prototype pipeline
  • Bachelor's Degree in Plastics, Mechanical, or Process Engineering or equivalent work experience
  • 3+ years experience in tool design or plastics process engineering
  • 3+ years experience as a mechanical designer with relevant plastic design experience
  • Knowledge of design factors that impact manufacturability (section thickness, draft, texture, gate type and location, ejector pin location, slides and lifters, etc.)
  • Knowledge of applied GD&T and statistical process control methods
  • Hands-on experience running a molding press, including mold qualification techniques such as cavity balancing, gate seal studies, process window studies and cycle time optimization
  • Ability to systematically troubleshoot using Ishikawa diagrams and Design of Experiments
  • Working knowledge of a variety of engineering grade plastic resins
  • Hands on experience with secondary operations or post molding processes such as sonic welding, pad printing, lamination, coating, plating, and assembly
  • Proficient in molding-oriented CAD and tool design
  • Experience in tool and die work or proficient with close-tolerance milling, turning, and wire EDM
  • Experience working with Asian contract manufacturers and a contact list of preferred vendors/partners
  • Experience with LSR (Liquid Silicon Rubber) molding
  • Experience with Metal Injection Molding (MIM) and / or Die Casting
  • Experience with other plastic processes such as extrusion, compounding, thermoforming, and high pressure forming
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