GERRELL & HARD LIMITED
Mold Flow Engineer
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Mold Flow Engineer
About the Role
We are seeking an experienced Mold Flow Engineer to support the design and development of injection-moulded plastic components and tooling across the full product lifecycle.
In this role, you will use Autodesk Moldflow and associated simulation techniques to optimise component design, tooling performance, manufacturability, and production efficiency.
You will play a key role in simulation-led engineering decisions from early concept stages through to approved off-tool parts, helping reduce tooling risk, improve quality, and support robust industrialisation outcomes.
Key Responsibilities
- Perform Moldflow simulations including Fill, Pack, Warp, Cooling, and Fibre Orientation analysis to support component and tooling development.
- Create high-quality meshed models using appropriate mesh strategies to maximise simulation accuracy.
- Build representative Moldflow models incorporating cooling circuits, inserts, feed systems, injection pressure profiles, and other tooling-specific features.
- Analyse simulation results and provide clear, actionable recommendations to design, tooling, and manufacturing teams.
- Identify moulding and tooling risks through simulation, including what-if and sensitivity studies, and recommend corrective actions.
- Optimise gating strategies, runner systems, cooling layouts, cycle times, and overall tool performance.
- Support Design for Manufacture (DFM) reviews for both new and existing plastic components.
- Collaborate with tooling engineers on mould design, venting strategies, material selection, and process parameters.
- Participate in design reviews and advise engineering teams on Mold Flow requirements throughout development phases.
- Produce technical reports and presentation materials to communicate analysis findings to internal stakeholders and customers where required.
- Support tooling GA reviews and mould trials, gathering process data to correlate simulation results with actual tool performance.
- Assist with root-cause analysis of moulding defects using Moldflow outputs and in-plant validation data.
- Act as a technical support resource, helping colleagues understand and effectively use Mold Flow outputs.
- Develop and maintain Moldflow best practices, templates, libraries, and workflows to support continuous improvement.
- Manage multiple simulation activities simultaneously while ensuring delivery to programme milestones.
- Work closely with suppliers, toolmakers, and injection-moulding partners to validate assumptions and align on technical standards.
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Key Performance Indicators
- Improve prediction accuracy for shrinkage, warpage, and dimensional outcomes to reduce tooling risk and improve mould performance.
- Strengthen internal Mold Flow capability and reduce reliance on external simulation support.
- Integrate Mold Flow outputs into wider engineering, tooling, and manufacturing workflows.
- Support simulation-led decision-making throughout product development, tooling validation, and launch phases.
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Preferred Skills & Experience
- Proven experience carrying out Moldflow simulations for injection-moulded plastic components.
- Strong proficiency in Autodesk Moldflow Insight.
- Ability to create fully meshed part and tooling models, including complex tooling features where required.
- Solid understanding of plastic component design, mould tool design, and injection-moulding processes.
- Strong knowledge of thermoplastics, fibre-filled materials, shrinkage behaviour, and warpage control.
- Excellent analytical and problem-solving skills.
- Strong communication skills with the ability to explain technical simulation results to non-specialist audiences.
- Experience managing multiple simulation projects within cross-functional engineering teams.
- Previous collaboration with toolmakers or injection-moulding suppliers.
- Experience correlating simulation results with mould trial and production data.
Desirable
- Degree or equivalent experience in Mechanical, Plastics, Manufacturing, or Materials Engineering.
- Knowledge of GD&T, DFM, DFA, or tolerance analysis.
- Familiarity with DOE methods, optimisation studies, or additional CAE tools.
This is an excellent opportunity to join a forward-thinking engineering team and contribute to the successful delivery of high-quality injection-moulded products through advanced simulation and tooling expertise.
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