{"id":1173711,"url":"https://alion.io/job/resmed-senior-engineer-moulding-engineering-research-technology","title":"Senior Engineer, Moulding Engineering – Research & Technology","company":{"id":99683,"name":"ResMed","domain":"resmed.co.uk","url":"https://alion.io/company/resmed-2","size_band":"5000+","is_staffing_agency":false,"is_intermediary":false,"listed_via":null,"ats_vendor":"Workday","truth_index":{"grade":"B","score":79,"open_postings":47,"ghost_share":0,"stale_share":0.83,"repost_share":0.021,"time_to_fill_p50_days":33,"computed_at":"2026-09-24T05:45:00Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"senior","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Sydney, Australia"],"countries":["AU"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":{"min_usd":79000,"max_usd":168000,"period":"year","method":"global_role_cell_scaled_by_country","sample_n":2945},"experience_years_min":null,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[],"status":"live","first_seen_at":"2026-09-24T09:48:42Z","employer_posted_date":"2026-09-24","last_verified_at":"2026-09-24T17:39:48Z","board_verified":true,"closed_at":null,"days_open":0,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":0},"description":"Let’s talk about the Team\nJoin our Moulding Research & Technology (R&T) Engineering Team and help develop the manufacturing capabilities needed for future Resmed products.\nThe R&T team explores and matures new moulding technologies before they enter formal NPI delivery. We work across materials, moulding processes, tooling, automation and product design to solve emerging manufacturing challenges and build scalable technology platforms.\nLet’s talk about the Role\nAs a Senior Engineer, Moulding Engineering - Research & Technology, you will lead the exploration, development and maturation of new moulding technologies, with a strong focus on Liquid Silicone Rubber (LSR) and related advanced manufacturing processes.\nYou will translate future product and manufacturing needs into technical experiments, prototypes and proof-of-concept processes.\nThe role focuses on taking technologies from early feasibility through production-relevant demonstration, then transferring mature technologies to NPI teams for product-specific industrialisation and validation.\nYou will combine scientific moulding principles, material knowledge and hands-on experimentation to build deeper understanding of process behaviour and develop robust, scalable manufacturing solutions.\nLet’s Talk About Responsibilities\nMoulding Technology Exploration\nIdentify and evaluate emerging moulding materials, processes, tooling technologies and manufacturing methods.\nDevelop proof-of-concept processes to test new ideas and manufacturing concepts.\nUse scientific moulding principles and structured experiments to understand process behaviour, material interaction and failure mechanisms.\nAssess technical feasibility, benefits, limitations and risks before recommending further development.\nProcess & Material Development\nDevelop and characterise new moulding processes, materials and process windows.\nUnderstand the relationship between material properties, tool design, moulding parameters and product performance.\nExplore technologies that can improve quality, productivity, sustainability and manufacturing flexibility.\nDevelop methods that reduce process complexity, secondary operations and energy consumption where practical.\nTooling & Rapid Experimentation\nWork closely with Tooling Design to develop experimental moulds, inserts and rapid tooling approaches.\nUse rapid prototyping and modular tooling concepts to shorten development cycles.\nSupport tool trials and use experimental data to improve mould, product and process design.\nApply simulation and engineering analysis where they can accelerate learning.\nTechnology Maturation & Design for Scale\nProgress promising technologies from laboratory feasibility toward production-relevant demonstrations.\nEvaluate technologies against future manufacturing needs including quality, cycle time, scalability, reliability, cost and sustainability.\nIdentify technical gaps that need to be resolved before NPI adoption.\nDevelop reusable moulding principles, standards and technology platforms where possible.\nSupport NPI teams during early adoption while enabling them to own product-specific industrialisation and process validation.\nCross-Functional Technology Development\nWork closely with Product Development, Tooling, Automation, Materials, NPI and Quality teams.\nInfluence product and tooling concepts early to improve manufacturability and scalability.\nShare technical learning across teams and manufacturing sites.\nTechnical Leadership\nAct as a moulding subject matter expert and mentor engineers in scientific moulding and process development.\nPromote structured experimentation and evidence-based decision making.\nBuild reusable engineering knowledge and strengthen Resmed’s long-term moulding capability.\nLet’s talk about you\nYou are a curious and hands-on engineer who enjoys solving problems that do not yet have established solutions.\nYou are comfortable experimenting, challenging assumptions and learning through iteration.\nYou combine strong moulding fundamentals with an understanding of materials, tooling and manufacturing systems.\nYou also understand that successful R&T is not only about proving that something can work once. It is about developing enough technical understanding so that the technology can later become a robust and scalable manufacturing capability.\nLet’s talk about Qualifications and Experience\nRequired\nBachelor’s degree in Polymer, Plastics, Rubber, Mechanical, Materials, Manufacturing Engineering or a related discipline.\nSignificant hands-on experience in injection moulding process development using scientific moulding principles.\nStrong understanding of injection moulding equipment, tooling, materials and auxiliary systems.\nExperience developing and troubleshooting moulding processes in a manufacturing or development environment.\nAbility to design structured experiments and analyse process data.\nStrong problem-solving and root-cause analysis skills.\nAbility to translate loosely defined technical challenges into clear experiments and development plans.\nStrong technical communication and cross-functional collaboration skills.\nCurious, independent, innovative and comfortable working through technical uncertainty.\nPreferred Qualifications\nStrong experience in Liquid Silicone Rubber moulding.\nExperience with thermoplastic injection moulding, multi-material or 2K moulding.\nExperience with silicone overmoulding, textile overmoulding or other advanced moulding technologies.\nExperience with mould flow simulation or other process simulation tools.\nExperience with rapid tooling, prototype moulds or modular tooling concepts.\nKnowledge of polymer/material characterisation and material-process interactions.\nExperience working with equipment, material and tooling suppliers.\nExperience developing technologies from proof of concept through production-relevant demonstration.\nMedical device or other regulated-industry experience is beneficial, although ownership of manufacturing process validation is not a core requirement for this R&T role.\nWhat Success Looks Like\nSuccess in this role means:\nRapidly determining which moulding technologies are worth pursuing.\nBuilding deeper technical understanding of new materials and processes.\nReducing technical uncertainty before NPI adoption.\nDeveloping reusable moulding technologies rather than one-off project solutions.\nInfluencing product and tooling design early to improve manufacturability.\nTransferring mature technology into NPI with clear evidence, process knowledge and risks.\nBuilding manufacturing capabilities that enable future Resmed products.\nJoining us is more than saying “yes” to making the world a healthier place. It’s discovering a career that’s challenging, supportive and inspiring. Where a culture driven by excellence helps you not only meet your goals, but also create new ones. We focus on creating a diverse and inclusive culture, encouraging individual expression in the workplace and thrive on the innovative ideas this generates. If this sounds like the workplace for you, apply now!We commit to respond to every applicant.","description_format":"text","description_chars":7084,"description_truncated":false,"requirements":{"experience_years_min":null,"management_years_min":null,"team_size_min":null,"manages_managers":false,"education":{"level":"bachelor","optional":false},"security_clearance":false,"languages":[]},"benefits":[],"hiring_locations":[],"hiring_excludes":[],"relocation_offered":false,"industries":["Health Care"],"lifecycle":[{"event":"open","at":"2026-09-24T09:48:42Z"}],"liveness":{"score":86,"band":"hot","label":"Hiring now","p_open":1,"p_active":0.86,"p_room":1,"age_days":0,"expected_fill_days":33,"reasons":["conf:0","win:early","comp:brand"],"computed_at":"2026-09-24T17:56:11Z"},"pay":null,"html_url":"https://alion.io/job/resmed-senior-engineer-moulding-engineering-research-technology","json_url":"https://alion.io/job/resmed-senior-engineer-moulding-engineering-research-technology.json","meta":{"generated_at":"2026-09-24T17:56:11Z","cache_seconds":300,"methodology":"https://alion.io/methodology","terms":"https://alion.io/terms","contact":"https://alion.io/contact","api":"https://alion.io/developers"}}