Graham Packaging is seeking a Design Engineer to serve as part of the Extrusion Product Development team. Graham commercializes hundreds of new packages every year, and each bottle requires a Design Engineer to create 3D models, 2D article drawings and simulations to predict part performance and process conditions. The Design Engineer is also responsible for utilizing cutting-edge design tools, such as 3D scanners for reverse engineering and 3D printers for developing quick prototype samples. He or she will be an expert in applying advanced CFD and FE modelling techniques to predict the rheology in plastic molding applications. The Design Engineer will also develop and advance techniques to predict the distribution of plastic under blow molding conditions. This position is based at Graham Packaging’s Global Technical Center in York, PA.
The primary duties of a Design Engineer - Extrusion include:
- Develop 3D models and engineering drawings for bottles, labels, closures, blow molds and plant gages
- Develop complex predictive simulation models via CFD and FEA software as part of standalone technical studies and the commercialization of new products
- Optimize blow mold designs through modeling the rheological behavior of extruded plastic in order to minimize mold closing forces and wear while maximizing the quality of the plastic pinch seal integrity, along with improving the mold’s heat-transfer and cooling circuit design/flow resulting in uniform part temperatures and predicable part shrinkages
- Optimize parison profiles through modelling of the blowing process in order establish process set-points that optimize the material distribution of blow-molded parts resulting in maximization of end product strength while minimizing weight
- Design and supervise physical tests in order to understand model applicability and limitations
- Collaborate with laboratories to conduct materials testing to better understand non-linear or incompletely documented materials characteristics
- Develop and document the fundamental knowledge of designing bottles through design rules, limit/tradeoff curves, engineering models, process maps and other tools while continuously improving new product development standards/standard work
- Perform engineering studies as part of the development process, analyze the results and write formal technical reports of highly complex information that will be shared with internal and external contacts
- Develop technically innovative solutions that improve the commercialization of new products and generate intellectual property
- Develop prototype models as part of the commercialization of new products, prototype molds used for lab sampling blow molders, and reverse engineer existing products by scanning bottles and creating 3D files
- Lead evaluations of new software and hardware for future integration
- Coach all engineers to apply developed models over a broad range of technical issue
Core Proficiencies and Skills
- The following skills and proficiencies are essential requirements of the position:
- Extensive experience in mechanical design using UGNX or other surfacing/solid modeling software
- Extensive experience in CFD using ANSYS Polyflow or other simulation software
- Extensive experience in FEA using UGNX, Blow-Sim or other simulation software (ABAQUS)
- Strong understanding of engineering principals
- Skilled in materials properties measurement and model correlation
- Skilled in free membrane shaping simulation such as vacuum forming or preform blowing
- Skilled in viscous material flow modeling (as might be required for press designs)
- Ability to develop technically rigorous engineering studies
- Strong written and verbal communication skills
- Experience managing highly technical projects in a fast-paced, collaborative, global team-oriented environment
- Strong knowledge of rapid prototyping including molds and models
- Experience in reverse engineering pertaining to scanners and scan data manipulation
- Travel up to 10% at times
Education and/or Work Experience Requirements
- BS degree in Mechanical Engineering (MS in Mechanical Engineering preferred)
- Extensive experience in mechanical design/development and predictive simulation, preferably in a highly technical industry (i.e. consumer products, medical devices, automotive, or heavy equipment design)
- Experienced in rheological material property testing techniques and results interpretation
- Experienced correlating actual versus theoretical results and model optimization
Graham Packaging Company Profile:
At Graham Packaging, our people drive packaging innovation for some of the most influential consumer brands in the world. To work with big brands, you need to be on the cutting edge, constantly reinventing the future and always willing to change.
Since our beginnings, this dynamic environment has forged a culture where you don't need to wonder where your next opportunity will come from -- the opportunities are all around you. All you have to do is take them.
With a global footprint of 100+ facilities across 16 countries and a committed team 7,000 strong, Graham Packaging offers you the ability to learn, the ability to grow and the ability to make your mark in a company that rewards doers, innovators and collaborators.
The above statements are intended to describe the general nature and level of work being performed by people assigned to this classification. They are not to be construed as an exhaustive list of all responsibilities, duties, and skills required of personnel so classified.
Graham Packaging is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, sex (including pregnancy), sexual orientation, religion, creed, age, national origin, physical or mental disability, gender identity and/or expression, marital status, veteran status or other characteristics protected by law.