Job Description
Job Description
Job Description
Senior Mold Designer & Toolmaker
Location: Westchester County NY
Employment Type: Full-Time
Position Overview
We are seeking an experienced Senior Mold Designer & Toolmaker to join our aerospace and defense electronics manufacturing team. This critical role supports the production of ultra-miniature transformers, inductors, power supplies, and magnetic components for military, aerospace, and mission-critical applications. The successful candidate will design and fabricate precision tooling for components that operate in extreme environments, from Mars rovers to submarine systems, requiring exceptional reliability and miniaturization expertise.
Key Responsibilities
Design & Engineering
- Design and develop ultra-precision injection molds and tooling for miniature magnetic components
- Create tooling for transformer housings, inductor enclosures, and power supply modules with dimensions as small as 0.31" x 0.31" x 0.34"
- Develop micro-molding solutions for components operating from -55°ree;C to +130°ree;C temperature ranges
- Design tooling for hermetic sealing applications requiring 100% vacuum impregnation processes
- Engineer solutions for molding around delicate magnetic cores, windings, and electronic assemblies
- Create precision tooling for surface mount and through-hole magnetic component packaging
- Design automated potting and encapsulation systems for extreme environment protection
Ultra-Miniature Component Manufacturing
- Fabricate tooling for components with wire gauges as fine as 52 AWG (less than 0.001" diameter)
- Develop solutions for molding magnetic shields and EMI suppression components
- Create precision fixtures for high-voltage applications up to 10,000V ratings
- Design tooling for power components ranging from 0.75W to 300W in ultra-compact packages
- Engineer solutions for military-grade reliability requirements (MIL-PRF-27, MIL-STD-202)
- Support manufacturing of components for QPL (Qualified Products List) certification
Advanced Precision Manufacturing
- Execute micro-machining operations for ultra-miniature component tooling with tolerances to ±0.0001"
- Operate CNC machining centers for precision cavity work in transformer and inductor molds
- Manage wire EDM processes for intricate details in magnetic component housing tools
- Implement specialized surface finishing for optimal magnetic field performance
- Maintain dimensional accuracy for components requiring 300+ thermal cycle reliability
- Execute precision assembly and testing of complex multi-cavity tooling systems
Military & Aerospace Quality Standards
- Ensure all tooling meets stringent military and aerospace manufacturing standards
- Implement quality control processes for components destined for fighter aircraft, spacecraft, and submarine systems
- Support manufacturing processes for components used in guidance systems and space applications
- Maintain traceability and documentation requirements for defense contractor specifications
- Coordinate with quality assurance for first article inspection and ongoing production validation
- Support customer audits and certification processes for aerospace and defense applications
Specialized Manufacturing Processes
- Design tooling for vacuum impregnation and potting processes unique to magnetic components
- Develop solutions for handling and molding magnetic materials and ferrite cores
- Create automated systems for precise winding insertion and core placement
- Engineer tooling for specialized lead configurations (gull wing, J-lead, surface mount)
- Support manufacturing of components for harsh environments including space, underwater, and high-vibration applications
Qualifications:
Technical Skills
- CAD/CAM Systems: Advanced proficiency in SolidWorks, MasterCam, and precision design software
- Micro-Machining: Expert-level skills in ultra-precision CNC programming and operation
- EDM Operations: Extensive experience with wire EDM for micro-scale component features
- Materials Science: Understanding of magnetic materials, ferrites, potting compounds, and high-temperature plastics
- Quality Systems: Knowledge of MIL-STD standards, QPL requirements, and aerospace quality protocols
- Measurement Systems: Proficiency with CMM, optical measurement, and micro-dimensional inspection
Education, Training & Qualifications
- Required: Technical diploma/certificate, completed apprenticeship, or equivalent hands-on training
- Preferred: Technical degree in Mechanical Engineering, Manufacturing Engineering, or Materials Science
- Minimum 10+ years of progressive experience in precision mold design and toolmaking
- Specialized training in magnetic component manufacturing or aerospace electronics preferred
- Familiarity with defense contractor requirements and security protocols preferred
- Experience with magnetic component design and electromagnetic field considerations
- Understanding of high-frequency transformer and inductor manufacturing
Compensation & Benefits
- Competitive salary commensurate with experience ($90,000 - $100,000+ depending on qualifications and clearance level)
- Comprehensive health, dental, and vision insurance with premium coverage
- 401(k) retirement plan with generous company matching
- Performance-based bonuses tied to mission-critical program success
Job Tags
Full time, For contractors,