Plastic Injection Molding & DFM Engineer - Small Plastic Enclosure Optimization

Job Title Plastic Injection Molding & DFM Engineer – Small Plastic Enclosure Optimization Job Description We are seeking an experienced Mechanical Engineer / Product Designer specializing in plastic injection molding to help optimize a patent-pending customer product for high-volume manufacturing. We currently have a basic concept design, structural layout, and rough measurements for a small plastic enclosure. We need a professional to fine-tune the geometry, optimize the design for manufacturing (DFM), and deliver production-ready 3D CAD files. The final product will likely be manufactured using either Polycarbonate or Acrylic, so deep knowledge of polymer characteristics, draft angles, wall thickness uniformity, and shrink rates is required. Key Technical Challenge: A critical challenge of this design is successfully accommodating a custom silicone gasket within a tight 2.5 mm (or preferably less) working area to ensure a proper watertight micro-seal. The ideal candidate must have proven experience calculating gasket compression, designing proper gland/groove dimensions, and managing tight tolerances. Key Responsibilities: - Review existing basic concept designs and structural measurements. - Optimize the design for injection molding (DFM), ensuring proper draft angles, radiused corners, and wall thicknesses. - Deliver two distinct 3D CAD variations: one optimized for high-volume injection molding, and one optimized for functional 3D printing/prototyping. - Advise on material selection (Polycarbonate vs. Acrylic) based on product/structural needs and impact resistance. - Deliver high-quality, production-ready 3D CAD models (STEP/IGES) and 2D technical drawings. Requirements: - Proven experience in plastic product design, enclosure design, and Design for Manufacturing (DFM). - Expert proficiency in SolidWorks, Fusion 360, or similar professional CAD software. - Strong understanding of Polycarbonate, Acrylic, and elastomeric/silicone sealing properties. - Must be willing to sign a Mutual Non-Disclosure Agreement (NDA) before project details or core concepts are shared. - Located in the United States. * Note: For this project, asynchronously communicating via text/messaging rather than phone or video calls is strongly preferred. *