Job Description

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About the Company

DSB Technologies, formerly known as SSI Sintered Specialties and headquartered in Janesville, Wisconsin, is a leading metallurgical solutions partner through three forming technologies: Press & Sinter, Metal Injection Molding, and Metal Binder Jetting. Our talented team of over 400 technical experts enable our global customer base to lead their industries with new technology that promotes a sustainable future. In our commitment to innovation, we are aggressively pioneering advanced metallurgical processes and technologies to unlock the full potential of material and product development. We have been on the leading edge of new innovations for powder metal components for over 50 years. In 2022, our company name evolved and our drive for collaborating, discovering, and innovating only intensified

About the Role

The 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.

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.

Qualifications

• Bachelors Degree in Materials Science, Mechanical Engineering, Chemical Engineering, or a related field.
• 35 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.

Required 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.).

Preferred 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.

Pay range and compensation package

Not specified in the provided job description.

Equal Opportunity Statement

We are committed to diversity and inclusivity in our hiring practices.

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