Job title: Principal DFM Engineer
Location: Lincolnshire, IL
About Us
Imagine a company with technology leadership of over 160 years, yet it operates with the energy of a startup. Ingersoll Rand has dedicated itself to Making Life Better for its employees, customers, shareholders, and planets. We produce innovative and mission-critical flow creation and life science technologies from compressors to precision handling of liquids, gasses, and powers to increase industrial productivity, efficiency, and sustainability. Supported by over 80+ brands, our products are used in various end-markets including life sciences, food and beverage, clean energy, industrial manufacturing, infrastructure, and more. Across the globe, were driving growth with an entrepreneurial spirit and ownership mindset. Learn more at irco.com and join us to own your future.
Job Overview:
The Principal DFM Engineer is responsible for driving design-for-manufacturability (DFM), process feasibility, and cost optimization for silicone and elastomer-based products across the organization.
This role serves as a subject matter expert and strategic leader, owning the quoting process from a technical standpoint while establishing the manufacturing strategy from proto@type through full-scale production. Responsibilities include developing detailed cost models, defining tooling approaches, estimating validation requirements, and translating customer designs into robust, scalable manufacturing solutions.
The Principal DFM Engineer plays a critical role in guiding cross-functional decision-making and influencing customer outcomes, directly impacting business growth, margin performance, and long-term capability development. While accountable for quotation and cost modeling, this position is primarily differentiated by its deep technical influence, shaping product design, tooling, and process strategies across the Elastomers Operation Unit. Additionally, this role advances best practices in LSR, HCR, and elastomer molding and extrusion technologies, particularly within regulated environments including Class II and Class III medical devices, while mentoring engineers and elevating organizational DFM capability.
.Responsibilities:
Design for Manufacturability (DFM) Leadership
Lead comprehensive DFM evaluations for elastomer components and assemblies, providing actionable recommendations to optimize:
Manufacturability and scalability
Yield, robustness, and quality
Cost efficiency and margin performance
Regulatory and validation readiness
Influence customer designs upstream through direct technical engagement and design reviews
Identify critical-to-quality features, tolerance risks, and process limitations
Define optimal manufacturing approaches across:
LSR injection molding
HCR molding (compression, transfer)
Extrusion and downstream operations
Multi-shot, overmolding, and bonded assemblies
Technical Costing & Quotation Leadership
Serve as the technical owner of RFQs, developing detailed, transparent cost models for proto@type through full production
Translate DFM decisions into:
Cycle time, cavitation, and capacity strategies
Tooling concepts and lifecycle strategies (proto@type vs production tooling)
Labor, material utilization, scrap, and secondary operations
Develop and present:
Multi-scenario pricing strategies (volume tiers, automation levels, tooling options)
NRE, validation (IQ/OQ/PQ), and lifecycle cost considerations
Partner with Sales and Business Development in customer-facing technical and commercial discussions
Ensure alignment between technical assumptions, cost structure, and business objectives
Tooling & Manufacturing Process Strategy Development
Define the end-to-end manufacturing strategy, including:
Prototyping approach and scale-up pathway
Tooling phases and capital investment strategy
Automation and inspection strategies
Validation and qualification roadmap
Define and evaluate tooling approaches:
Multi-cavity vs. family molds
Cold runner systems, gating, venting, and parting line strategies
Steel selection, mold class, and lifecycle considerations
Collaborate with Process Engineering, Tooling, Quality, and Operations to:
Validate manufacturability assumptions
Optimize cycle time, yield, and throughput
Drive early-stage decisions that impact long-term operational efficiency, cost, and capacity
Cross-Functional Technical Leadership
Act as a technical bridge across:
Sales / Business Development
Engineering (Process, Tooling, Project)
Quality (validation, regulatory requirements)
Supply Chain (materials, MOQs, lead times)
Lead technical reviews during RFQ, contract review, and NPI phases
Ensure manufacturability, cost, and quality assumptions are clearly documented and transferred into execution
Continuous Improvement & Cost Optimization
Drive should-cost modeling and cost-out initiatives though improved mold designs, optimized cycle times, or new automation opportunities
Analyze quote-to-actual performance and refine estimating accuracy
Establish and standardize:
DFM guidelines
Costing methodologies
Quoting best practices and templates
Identify and implement improvements in:
Tool design
Process efficiency
Material utilization
Automation strategies
Technical Mentorship & Organizational Impact
Mentor and develop engineers in DFM, elastomer processing, and cost engineering
Serve as a subject matter expert (SME) for silicone and rubber processing technologies
Support capability development and capital investment planning
Contribute to long-term technology roadmaps and strategic growth initiatives
Requirements:
Bachelors degree in Engineering (Mechanical, Manufacturing, Materials, Polymer, or similar)
10+ years of experience in elastomer manufacturing, DFM or process engineering
Deep expertise in:
Silicone (LSR, HCR) and rubber materials
Compression, transfer, and injection molding processes
Tooling design principles (cavitation, gating, venting, materials)
Cost modeling and estimating for elastomer components
Proven experience in
Validation requirements (IQ/OQ/PQ), APQP, PPAP
Interpreting engineering drawings, GD&T, and 3D CAD models
Regulatory and customer specifications (medical preferred)
Experience working in cross-functional and customer-facing roles
Proficiency with CAD tools (e.g., SolidWorks)
Preferred
Experience in medical device manufacturing (Class II / Class III)
Experience in technical quoting and cost modeling
Experience with:
Mold flow analysis and interpretation
Automation and high-volume manufacturing systems
Multi-material molding (overmolding, bonding, insert molding)
Experience in CDMO environment
Six Sigma or Lean Manufacturing certification
Key Competencies
Strong technical and commercial acumen
Advanced problem-solving and analytical skills
Ability to influence internal and external stakeholders
Excellent communication with both technical and non-technical stakeholders
High level of ownership, accountability, decision-making authority
Strategic mindset with attention to detail
Travel & Work Arrangements/Requirements
Fully site based
The pay range for this role is $100-$150k, excluding incentive opportunities. The pay range takes into account a wide range of factors that are considered in making compensation decisions including, but not limited to, skills; experience and training; licensure and certifications; and geographic location. Hired applicant will be eligible to receive (discretionary/nondiscretionary) annual bonuses and incentive compensation.
What we Offer
At Ingersoll Rand, we embrace a culture of personal ownership taking responsibility for our company, our communities, and our environment, as well as our individual health and well-being. Our comprehensive benefits package is designed to empower you with the tools and support necessary to take charge of your health, ensuring that together, we can continue to make life better. Our range of benefits includes health care options like medical and prescription plans, dental and vision coverage, as well as wellness programs. Additionally, we provide life insurance, a robust 401(k) plan, paid time off, and even an employee stock grant, among other offerings. These benefits are our commitment to you, so you can be your best at work and beyond.
TO APPLY : Please apply via our website (provide hyperlink or URL) [or list other application portal/contact info for designated contact] by [Date] in order to be considered for this position.
