Sr Process Engineer | Overmolding Focus | Power

Role Purpose

Lead the definition, development, and optimization of manufacturing processes for power cable assemblies, with a strong focus on cable overmolding and molding technologies, across product development, production line transfer, and sustaining manufacturing. Partner closely with Product Development to ensure designs are optimized for overmolding manufacturability, tooling capability, scalability, and long-term production robustness.

Key Responsibilities

• Define, document, and release cable assembly and overmolding processes during product development, NPI, and line transfer
• Lead development, optimization, and validation of cable overmolding tooling, processes, and parameters
• Provide design alternatives and recommendations to Product Development based on molding and overmolding capabilities
• Support DFM and DFA activities related to cable routing, strain relief, material flow, and encapsulation robustness
• Provide hands-on technical leadership during line ramp-up and sustaining production for overmolded cable assemblies
• Troubleshoot overmolding and cable assembly issues such as voids, adhesion, flash, deformation, and dimensional variation
• Support cycle time optimization, yield improvement, and process capability for molding and overmolding operations
• Provide technical input and countermeasures to PFMEA and Control Plans related to cable assembly and overmolding
• Introduce fixtures, jigs, and process improvements to enhance quality, efficiency, and repeatability
• Participate in sample builds, First Article, and transfer validation activities

Scope & Authority

• Technical ownership of cable assembly and overmolding process definition from product development through sustaining production

• Authority to recommend and implement process and tooling improvements within approved design boundaries

• Authority to provide design guidance and alternatives based on molding and overmolding process capability