Job Responsibilities:JOB SUMMARY:The Tool Engineer at Magna Engineered Glass is responsible for leading the technical development, procurement, validation, and continuous improvement of tooling used in the manufacture of encapsulated glass automotive windows. This role ensures all tooling (prototype, soft-tool, and production) is designed, built, sampled, and approved in compliance with Magna, customer, regulatory, and safety standards. The position requires specialized expertise in injection molding of encapsulated glass, including mold design, material behavior, glass loading, adhesion performance, sealing, and overmold processes.
The Tool Engineer collaborates with Product Engineering, Program Management, Supplier Quality, Manufacturing Engineering, and Tooling Suppliers (domestic and international) to ensure world class tool builds, robust manufacturability, and flawless launch execution.
JOBRESPONSIBILITIES:`- Tooling Development & Standards
- Maintain and apply corporate tooling standards for injection molded encapsulation tools.
- Identify, evaluate, and maintain qualified tooling suppliers with demonstrated capability in encapsulated glass molding, including vertical presses, robot assisted glass loading, and automated demold.
- Develop and validate new tooling processes including:
- Encapsulation overmold of automotive glass
- Dynamic pressure pad systems
- Magnetized bezel or stiffener insert molding
- Soft seal tooling and integrated glass fixturing systems
- Lead mold design reviews; verify parting lines, gating, runner systems (hot & cold), steel selection, shrink rates, cooling strategy, and texturing requirements.
- Ensure tool designs incorporate requirements for glass edge protection, dimensional stability, adhesion performance, and sealing surfaces.
- Maintain complete data retention: 2D/3D tool designs, CMM reports, process sheets, hot runner data, and material/manifold documentation.
- Manufacturability & Product Integration
- Evaluate new product quotes for feasibility of glass encapsulation molding, including:
- Glass edge tolerances and flatness
- Cross section design for seals, beads, and retention features
- Adhesion and overmold bonding requirements
- Gate location impact on flow induced stresses in glass and polymer
- Collaborate with Designers, Program Managers, Tooling Suppliers, and Project Engineers to ensure product design supports robust encapsulation manufacturability.
- Participate in product design reviews to confirm draft, shut offs, retention geometry, gaging datums, and warp/shrink predictions meet customer specifications.
- Tool Build Management & Launch
- Prepare, manage, and approve tooling quotes for encapsulation tools within the corporate system.
- Track tool builds through timing plans, supplier visits, milestone reviews, and PPAP readiness.
- Lead sampling and launch of new tools including:
- Glass loading validation
- Overmold sealing performance
- Adhesion / peel testing
- Tool debug for short shots, flash, sinks, voids, and stress marks
- Validate tooling and equipment through CMM layout, glass fixture verification, and encapsulation profile conformance.
- Oversee texture (grain) approvals and surface quality reviews.
- Define and release spare parts, preventive maintenance plans, and critical spare steel.
- Support packaging, racking, and gage design reviews.
- Analysis, Testing & Supplier Interaction
- Direct Mold Flow and CAE studies specific to encapsulated glass:
- Flow front around glass substrate
- Knit line and adhesion risk areas
- Cooling of non uniform wall sections
- Polymer stress transfer into glass edges
- Maintain material line cards including TPE, PVC, PC/ABS, TPU, and specialty encapsulation compounds.
- Support supplier tool builds, including on site assessments of mold design, machining quality, tryout equipment, and process capability.
- Support component and system testing including:
- Glass adhesion pull tests
- Weathering & UV durability
- Thermal cycling and expansion mismatch evaluation
- Troubleshoot issues for existing programs (e.g., de lamination, glass cracking, warp, dimension failures).
- Participate in formal supplier evaluations after project completion.
- Documentation & Reporting
- Document all technical decisions, tool modifications, sampling results, and validation activities.
- Maintain accurate, updated timing charts and project status for all assigned tools.
- Prepare cost reports, variance analyses, and support budgeting and forecast activities.
- Process & Continuous Improvement
- Maintain expertise in emerging encapsulation tool technologies, such as:
- Advanced hot runner systems for hybrid materials
- Tool steel performance for glass contact areas
- Adhesion promoting surface treatments
- Support implementation of new materials including TPE, low gloss PVC, PC/ABS, and future encapsulation compounds.
- Develop and update work instructions, quality procedures, and tooling standards related to encapsulated glass molding.
- Train Tool Room personnel on encapsulation tool maintenance, repair methods, PM frequency, and safe handling of glass molds.
- Compliance & Safety
- Adhere to all Magna Engineered Glass' safety policies and environmental regulations.
- Follow ISO/IATF 16949 and ISO 14001 requirements.
- Participate in required safety and environmental training.
- Perform additional duties as assigned to support departmental and organizational goals.
- Actively contribute to a positive and collaborative work environment, demonstrating flexibility to adapt to evolving business needs and priorities.
REQUIREMENTS:- Bachelor's degree in Engineering or related technical field highly preferred, experience in lieu of may be considered.
- 8+ years of experience in tooling, plastics, or program engineering within a manufacturing environment, with deep expertise in injection molding of encapsulated automotive glass.
- Advanced knowledge of injection mold design, polymer behavior, and manufacturing processes, including mold flow/CAE interpretation.
- Expert understanding of glass handling and fixturing, polymer-to-glass adhesion mechanisms, overmold material selection, and mold design strategies for encapsulated windows.
- Proven experience leading complex, multi-tool programs, including supplier management and budget responsibility.
- Ability to manage multiple tooling programs simultaneously while ensuring quality, timing, and cost targets are met.
- Strong ability to interpret and apply engineering drawings, CAD models, and tooling layouts.
- Demonstrated capability to develop, present, and support advanced tooling concepts, continuous improvement initiatives, and long-term manufacturing strategies.
- Strong communication, documentation, and organizational skills, with the ability to work effectively both independently and in cross-functional teams.
- Knowledge of safety standards and protocols in manufacturing environments.
- English proficiency required, with strong verbal and written communication skills. Bilingual (Spanish) preferred.
WORK ENVIRONMENT:- Office Environment: 60%
- Plant Environment: 40%
- It requires (Near/Far/Depth/Color) vision in order to be able to tolerate the eye strain associated with working on a computer throughout the workday.
- Must be able to tolerate the use of a keyboard and mouse on average of 6 hours per workday.
- While working in the Plant environment, the employee will be exposed to machinery, moving equipment and material, moderate noise, airborne particles, fumes, and various levels of temperature created by the manufacturing process.
- This role operates primarily in a manufacturing facility. Occasional travel may be required visit suppliers or other specific purposes. Travel requirements for this position are estimated at 5-10% and may include both domestic and/or international destinations as needed.
PHYSICAL DEMANDS:- The employee must be able to tolerate sitting and standing for extended periods of time, as well as walking, bending, and other physical movements required to perform the essential functions of the role.
- Prolonged standing at least 8 hours, but up to 12 hours per day
- Lift objects weighing up to 40 pounds multiple times per day.
- Repetitive bending, twisting, turning, lifting.
- Repetitive use of hands, including gripping, grasping, pinching, squeezing
KEY COMPETENCIES:A competency is a specific behavior or attribute that enables someone to effectively perform tasks or fulfill responsibilities in a job role. Each competency represents a key area in which an individual must excel to succeed in a role, and Magna Engineered Glass often uses competencies as benchmarks for assessing employee performance, guiding professional development, and aligning workforce capabilities with organizational goals.
- Technical leadership in injection molded encapsulation tooling.
- Expertise in reviewing mold designs, evaluating manufacturability, and problem solving tooling issues.
- Strong cross functional communication and supplier management.
- Ability to integrate requirements for glass, polymer, and tooling to ensure robust production.
