Plastics Engineering Co-Op

Role details

At Sussex IM, our people are everything. We believe that a strong culture rooted in trust, accountability, and teamwork is the foundation for long-term success. That’s why we invest in our employees with hands-on training, advancement opportunities, and a work environment that values safety, integrity, and open communication.

We’re proud to be a plastic injection molding company where people come to build careers, not just punch a clock.

If you wish to submit your resume for any of these openings, please email: [email protected]

Summary of Position

The Plastics Engineering Co-Op supports the Molding Engineering team across the full life of a mold, from new product development through production. The co-op works under the direction of the Molding Engineering Manager, with day-to-day guidance from the NPD and production process engineers.

On the NPD side, the co-op runs molding simulations, takes part in part and mold design reviews, and supports tooling and mold trials. On the production side, the co-op supports process documentation, troubleshooting, and continuous improvement. Assignments are scoped to the co-op term and include at least one defined project, presented to engineering and manufacturing leadership at the end of each term. Responsibility increases with each returning rotation.

Essential Duties, Responsibilities, & Authority

• New Product Development (NPD) Support

• Runs filling, packing, cooling, and warp simulations under the guidance of the NPD Process Engineer, and compares simulation predictions with actual molding results to support correlation.
• Uses simulation results to support quoting and new mold decisions, including cycle time, press tonnage, and gate location estimates.
• Participates in part design reviews, evaluating wall thickness, draft, ribs, bosses, gate location, knit lines, and potential sink or warp, and documents recommendations for customer feedback.
• Assists with process development on new molds using the scientific molding principles
• Supports the handoff of new molds from NPD to production, including process sheets and setup documentation for release.

• Tooling Support

• Participates in mold design reviews with tooling engineers, mold builders, and toolmakers, covering gating, runners, cooling layout, venting, and ejection.
• Supports mold trials and sampling (T0, T1, and subsequent trials) by helping set up trials, collecting process data, measuring parts, and documenting results and open issues.
• Tracks tooling issues and mold modifications from trial findings through correction and verification.
• Learns mold construction and components (hot runners, cooling, ejection, slides and lifters) through time with the toolroom.

• Production Process Support & Troubleshooting

• Assists process engineers in maintaining process sheets, process windows, and setup documentation for released molds.
• Supports Scientific Molding studies (viscosity, gate seal, pressure drop, cooling studies) by setting up trials, collecting data, and organizing results.
• Works alongside engineers and technicians on problem jobs to learn how defects such as flash, sinks, shorts, splay, voids, warp, and dimensional issues are diagnosed, and whether the root cause is process, material, mold, or machine.
• Assists with root cause and corrective action (RCCA) investigations by gathering data, measuring parts, and documenting findings using tools such as 5-Why and fishbone diagrams.
• Learns medical molding requirements as they apply to assigned projects.

• Continuous Improvement

• Completes one or more assigned projects per term (NPD, tooling, or production CI focused on scrap, cycle time, uptime, or capability), from baseline data through results.
• Pulls and analyzes production data (scrap, downtime, cycle, Cpk) from IQMS and the floor, and verifies data against floor observations.
• Presents project results to engineering and manufacturing leadership at the end of each term.
• Learns, practices, and supports Lean Manufacturing tools to assist the company in the CI process.

• Documentation & Training Support

• Drafts and updates work instructions, setup procedures, and training materials in Sussex IM’s ISO document format for review and approval by engineering.
• Completes required paperwork accurately (trial reports, setup and start-up checklists, press logs).

General Responsibilities

• Works closely with NPD, Tooling, Quality, Maintenance, and Production to complete assignments and align on priorities.
• Promotes actions in accordance with the company’s core values by leading through example.
• Follows Sussex IM’s environmental policies to protect and minimize our impact on the environment.
• Maintains a safe and 5S’d working environment to minimize the possibility of an injury. Always acts in a safe manner and ensures that those around them do not put themselves or others at risk. Reports any unsafe conditions to a manager.
• Performs other related duties and assignments as assigned or required.

Required Education, Credentials, & Certifications

• Currently enrolled in a bachelor’s degree program in plastics, polymer, mechanical, or manufacturing engineering, or a related engineering technology field, and eligible for co-op through the school’s program.
• Completion of at least [two] years of the degree program preferred; coursework in polymer materials, plastics processing, or mold design a plus.
• Scientific Molding or simulation coursework or training a plus but not required; training will be provided.

Job Specification

• No prior injection molding experience required; previous manufacturing, co-op, or hands-on technical experience a plus.
• Available for a full-time co-op term of [X] months beginning [term]; availability for additional returning rotations preferred.
• Must be able to work with multiple departments and support trials on other shifts as needed.
• Must have an open mind and willingness to learn.

Knowledge, Skills & Abilities

• Working computer skills in Microsoft Office, especially Excel; exposure to IQMS or another ERP system a plus.
• Exposure to 3D CAD (e.g., SolidWorks) and the ability to read part and mold drawings, including basic GD&T.
• Exposure to mold flow simulation software (e.g., Cadmould, Moldflow) a plus.
• Basic understanding of polymer materials, part design, and the injection molding process, or a strong interest in learning them.
• Mechanical aptitude and comfort working hands-on at the press and in the toolroom.
• Basic statistics knowledge (averages, standard deviation, SPC concepts).
• Uses good interpersonal communication techniques to work with technicians and/or coworkers. Is courteous and helpful when interacting with fellow employees. Helps to create a positive work environment.
• Must have good documentation skills.
• Critical thinking and root cause problem-solving skills.
• Ability to gather data and think creatively.
• Ability to lift to 75 lb. to shoulder height.
• Good attendance and punctuality.

What guides us every day

• How Can I Help?
• Treat Everyone Like Family
• Work Hard, Play Hard, Laugh Hard
• If We Can, We Will… and Then Some
• Own the Outcome, Share the Credit
• We’ll Figure It Out

Competitive Benefits for Full-Time Employees

Sussex IM offers a comprehensive benefits package that supports the health, well-being, and financial security of our team members.

Health & Wellness

• Medical, dental, and vision insurance
• Health Savings Account (HSA)
• Onsite Aurora Clinic
• Health club reimbursement
• Camp SIM program
• Zoo pass access

Financial & Retirement

• 401(k) with company match
• Profit sharing
• Bonus plans
• Tuition reimbursement

Time Off & Recognition

• 11 paid holidays
• Paid vacation
• Length of service recognition
• Core Value program

Community & Culture

• Company picnic and events
• Employee meals
• Supportive, cross-functional teams