Simulation Engineer – Injection Molding (XR Optics) - #1174083

Role Summary

Perform mold flow simulation and validate injection molding trials for structural components and optical lenses used in XR display modules. Identify molding risks early, optimize tooling and process parameters, and support the transition from mold design to stable mass production. The role focuses on shortening tooling development lead times, improving lens surface-form accuracy, and increasing the dimensional pass rate of structural components.

Key Responsibilities

1. Perform mold flow simulation. Build simulation models from 3D part geometry and material data. Analyze filling, packing, cooling, warpage, and fiber orientation as applicable. Identify risks such as sink marks, weld lines, warpage, and air traps. Document findings and lead simulation reviews.

2. Optimize optical lens molding. Simulate multi-stage injection, switchover to packing, and cooling rates. Assess residual stress and birefringence risks, evaluate how process settings affect lens surface-form accuracy (PV/RMS), and recommend a molding process window.

3. Support mold design and design for manufacturability (DFM). Recommend improvements to gate locations, runners, cooling channels, and venting. Evaluate flow balance across cavities and advise on tool steel and surface treatments. Track agreed design changes through closure.

4. Plan and support molding trials. Coordinate T0, T1, and final tooling trials with internal teams and suppliers. Set initial machine parameters based on simulation, troubleshoot defects on site, and record process settings and sample quality results.

5. Resolve molding defects and validate corrective actions. Investigate root causes, run design of experiments (DOE) to optimize process settings, and verify improvements in follow-up trials. Compare predictions against measured lens surface form, part dimensions, and residual stress. Document approved settings and defect countermeasures.

6. Standardize simulation and trial validation. Maintain a material database covering viscosity, pressure–volume–temperature (PVT) behavior, and shrinkage. Establish simulation workflows, reporting templates, and a process for comparing simulations with trial results. Track new molding technologies and share technical findings with the team.

Qualifications

• Bachelor’s degree or higher in Materials Forming and Control Engineering, Polymer Materials and Engineering, Mechanical Engineering, Mold Design and Manufacturing, or a related discipline.

• Proficiency in at least one mold flow simulation tool, such as Autodesk Moldflow, Moldex3D, or CADMOULD. Proficiency in Creo or Siemens NX (UG) for reviewing tooling geometry.

• Strong foundation in polymer rheology and heat transfer, with the ability to translate simulation results into tooling changes and practical molding settings.

• Knowledge of optical-grade polymers such as COC, COP, PMMA, PC, and OKP, and structural polymers such as PC, glass-fiber-reinforced PC, PA, LCP, and PBT.

• Hands-on experience setting up and tuning injection molding machines, troubleshooting molding defects, and using DOE to optimize process settings.

• Familiarity with precision mold design, optical interferometry for lens surface-form measurement, coordinate measuring machines (CMMs), and polariscopes for residual stress assessment.

• Ability to independently manage simulation and tooling trial work and coordinate technical decisions with tooling, mechanical design, optical design, process engineering, quality, and external suppliers.