Manufacturing Technology Engineer

Manufacturing Technology Engineer – Injection Molding & Tooling 

About Us 

AFL manufactures industry-leading fiber optic cable, connectivity, and accessories, and provides engineering and installation services for some of the largest telecom customers in the world. Founded in 1984 with a single fiber optic cable, we now manufacture thousands of products, generate in excess of $3 Billion in revenue, and employ approximately 12,000 associates worldwide. 

At AFL, we recognize that our employees are our greatest asset. We hire and train each individual, investing in them to ensure success in their careers. With a commitment to professional development and growth, let us connect you to your next career opportunity. 

What We Offer 

• Flexibility: Hybrid work schedule for qualifying employees and flexible time off policy. 

• Financial Security: 401K company match up to 4% (dollar-for-dollar match). 

• Growth: Professional development, training, and tuition reimbursement programs. 

• Health & Wellness: Excellent medical, dental, vision, and life insurance policy options. 

• Advancement: Opportunities for career progression with an industry leader. 

Job Summary 

The Manufacturing Technology Engineer – Injection Molding & Tooling is a technical authority overseeing AFL’s external global network of outsourced molding and tooling suppliers. Operating at the critical intersection of New Product Development (NPD), Supply Chain, and external manufacturing, this role is responsible for the design, build, commissioning, and maintenance of injection and compression mold tooling across the product lifecycle. 

This position requires a "hands-on" technical expert who will work closely with Product Development and Design Engineering to optimize plastic part design, mandate robust DFM standards, approve tool designs, and manage the technical validation process to evolve AFL's telecommunications product portfolio. 

Key Responsibilities 

1. New Product Development & DFM Partnership 

• Design Optimization: Partner directly with Product Development and Design Engineering early in the product lifecycle to optimize plastic part designs for injection and compression molding. 

• DFM Leadership: Lead comprehensive Design for Manufacturability (DFM) reviews covering features, draft angles, wall thickness uniformity, gating locations, knit lines, and sink management. 

• Simulation Analysis: Review and interpret Moldflow simulations (fill, pack, warp, and cooling) to make data-driven design decisions before tooling kickoff. 

1. Tooling Procurement & Supplier Management 

• RFQ Strategy: Author technical RFQ packages for new tooling, specifying mold classifications (SPI Class 101/102), steel types, cavitation strategy, and hot/cold runner systems to obtain precise tooling and part quotes. 

• Primary Interface: Act as a primary technical interface between AFL, external toolmakers, and third-party molders to scope, implement, and track tooling changes. 

• Project Management: Lead projects to design, build, and commission mold tooling, tracking schedules to ensure suppliers hit critical milestones from steel cutting through tool acceptance. 

1. Mold Design Approval & Tooling Validation 

• Design Approvals: Critically review and formally approve detailed 3D mold designs and modifications submitted by external vendors, verifying parting lines, cooling line layouts, slider/lifter mechanisms, and ejection systems. 

• Quality Validation: Support engineering and quality teams during the plastic part approval process. Review FAI, IQ/OQ/PQ validation protocols, and Statistical Process Control data (Cpk). 

• Hands-on Troubleshooting: Travel to external tool machine shops and supplier molding facilities to troubleshoot sample runs, resolve defects, and optimize process windows using scientific molding principles. 

1. Material Selection & Lifecycle Support 

• Material Strategy: Provide expertise on plastic material properties and resin selection (e.g., Polycarbonate, ABS, blends, glass-filled resins) tailored for telecom and fiber optic environments. 

• Sustaining Engineering: Work collaboratively with Product Engineering to scope and implement changes to released injection and compression tooling, using engineering analysis to solve complex, real-world failures. 

• Safety & Compliance: Work within an ISO-9001 quality management system environment and strictly adhere to and promote the environmental, health, and safety policies of AFL. 

Personal Qualities 

• Initiative: A self-starter with a willingness to take on additional responsibilities and drive projects forward independently. 

• Teamwork: Collaborates effectively in a cross-functional team environment featuring product management, quality, and manufacturing engineering. 

• Communication: Possesses strong written, verbal, and interpersonal influencing skills to align internal and external stakeholders. 

• Detail-Oriented: Demonstrates a high level of precision and rigorous attention to detail in tool designs, data analysis, and drawing reviews. 

• Flexible: Mentally agile and able to quickly adapt to shifting project priorities, deadlines, and business needs. 

Required Qualifications 

• Education: Bachelor of Science in Mechanical Engineering, Plastics Engineering, or a highly relevant technical discipline. 

• Experience: Minimum of 3+ years (7+ preferred for Senior level) of dedicated experience designing, building, and/or troubleshooting injection mold tooling. 

• Hands-On Foundation: Proven physical troubleshooting experience in a tool room, mold-making shop, or injection molding shop floor operations. 

• CAD Proficiency: Solid experience with parametric solid modeling (SolidWorks highly preferred) to interrogate, review, and modify complex plastic part and tooling designs. 

• Technical Knowledge: Robust understanding of plastic part design practices, plastic material properties, metrology, and mold flow simulation. 

• Quality Systems: Experience working within an ISO-9001 quality management system. 

• Travel: Ability to work in an office environment with a willingness to travel up to 25% domestically and internationally to audit suppliers and support tool builds. 

Preferred Skills & Experience (Not Required) 

• 5+ years of experience designing and/or building injection and compression mold tooling. 

• 2+ years of direct experience designing plastic parts. 

• Fiber optic industry experience, specifically regarding telecom design, development, and/or component applications. 

 

Equal Opportunity Employer Statement 

AFL is an Equal Opportunity Employer. The contractor will not discharge or in any other manner discriminate against employees or applicants because they have inquired about, discussed, or disclosed their own pay or the pay of another employee or applicant. However, employees who have access to the compensation information of other employees or app)  

licants as a part of their essential job functions cannot disclose the pay of other employees or applicants to individuals who do not otherwise have access to compensation information, unless the disclosure is (a) in response to a formal complaint or charge, (b) in furtherance of an investigation, proceeding, hearing, or action, including an investigation conducted by the employer, or (c) consistent with the contractor’s legal duty to furnish information. 41 CFR 60-1.35(c