R&D Engineer II

Why Tessy?

Since 1973, Tessy Plastics has been a global leader in injection molding and custom automated assembly solutions, partnering with top brands across the Medical, Pharmaceutical, Diagnostics, Consumer Healthcare, and Consumer markets.

With 3.2M+ sq. ft. of FDA/GMP-compliant facilities and operations in the U.S. and China, we turn complex ideas into high-performance manufacturing solutions – and we’re just as proud to be a great place to build a career.

Your Role at Tessy

The Research and Development Engineer II is responsible for developing and refining product designs that meet customer requirements and are optimized for manufacturability, including determining design and tooling specifications, selecting appropriate rapid prototyping methods, and providing design-for-manufacturability guidance directly to customers.

This role involves collaborative work across Sales, Automation, Quality, and Engineering departments to support quoting for prototype molds, work cells, and potential automation solutions, as well as providing ongoing engineering and technical support throughout development and characterization efforts. The position also encompasses the design, build, and characterization of pilot manual/semi-automated cells while integrating new technologies to continuously enhance molding and assembly processes.

What You’ll Be Doing

• Program Strategy & Full Ownership – Determine product design specifications, define TRL levels and the path to pilot/production, and outline departmental handoffs; establish clear work plans, anticipate challenges, and organize resources efficiently. Own full development programs encompassing proto mold/demold strategy, lab operations, pilot automation, fixture design, drawings, and data validation, exercising authority and accountability to ensure customer interactions instill confidence across internal and external Tessy teams.
• DFM Strategy & Tooling Specifications – Define and drive DFM strategy for proto-mold and production opportunities, including design, build, procurement, pilot process development, and cycle time optimization; verify sample quality with QA on official metrology and select optimal rapid prototype technologies to confirm design intent. Determine and confirm development tooling specifications for molding and secondary operations, understanding how tooling decisions impact profitability and program outcomes.
• Customer Reporting & TRL Documentation – Collaborate with customers to define requirements and deliver clear, precise reports documenting TRL readiness and achievement of established requirements through engineering studies, R&D reports, trials, and other technical documentation; communicate findings tactfully and effectively at all levels.
• Pilot Processes, OEM Interface & Materials Knowledge – Serve as SME and primary technical interface with customers through TRL 1–3, transitioning ownership to NPD Automation at TRL 4, with continued R&D support beyond for OEM automation efforts. Apply advanced resin material knowledge to drive selection based on performance, cost, and manufacturability, identifying and evaluating new polymer compound opportunities.

What You’ll Bring

• College Degree with 5+ years of experience highly desired OR High School Diploma/GED with 7+ years of experience.
• Proficiency in a 3D CAD package (e.g., SolidWorks, Autodesk Inventor, Siemens NX, or equivalent).
• Broad knowledge surrounding driving product development via pilot to scaled automation platforms.
• Medical device Quality systems knowledge surrounding design/history through manufacturing concluding at customer delivery preferred. FDA, ISO standards, PFMEA’s, CAPA.
• Strong attention to detail with a high degree of accuracy.
• Ability to apply logical and scientific thinking to a wide range of problems.
• Advanced problem-solving skills with the ability to systematically identify root causes of molding and assembly issues
• Toolroom equipment experience related to prototype development activities preferred.

Compensation

Salary Range: $90,000–$150,000.

The range displayed on each job posting reflects the minimum and maximum target base pay for new hire salaries of the position. This position may also be eligible for discretionary bonuses. Within the range, individual pay is determined by additional job-related factors, including knowledge, skills, experience, tenure and relevant education or training. The pay scale is subject to change depending on business needs. Your Recruiter can share more about the specific salary range or benefits during the hiring process.

Benefits

· Health, Dental & Vision Insurance: 100% employer-paid for employee-only coverage, +1 and Family coverage options available

· Additional Incentives: Quarterly profit-sharing program

· 401K Company match

Applicants must be authorized to work for any employer in the U.S. We are unable to sponsor or take over sponsorship of an employment visa at this time.