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Key Responsibilities and Required Skills for Mold Maker

💰 $45,000 - $85,000

ManufacturingToolingMaintenance

🎯 Role Definition

A Mold Maker is a skilled tradesperson responsible for designing, fabricating, assembling, testing, repairing, and maintaining precision molds and tooling used in injection molding, compression molding, die casting, and other production processes. The role requires advanced machine shop capabilities (CNC milling/turning, EDM, grinding), blueprint and CAD interpretation (GD&T), hands-on troubleshooting, and close collaboration with engineering and production teams to ensure molds meet dimensional, cosmetic, and cycle-time requirements. Successful candidates combine technical toolmaking expertise with strong problem-solving, documentation, and continuous improvement instincts.

📈 Career Progression

Typical Career Path

Entry Point From:

  • CNC Machinist or CNC Operator
  • Tool & Die Apprentice or Machining Apprentice
  • Injection Molding Technician or Production Operator

Advancement To:

  • Senior Mold Maker / Lead Toolmaker
  • Mold Maintenance Supervisor / Tooling Supervisor
  • Tooling Manager / Manufacturing Engineering Lead

Lateral Moves:

  • Process Engineer (injection molding/process optimization)
  • Maintenance Technician or Maintenance Planner
  • Quality Engineer (metrology and inspection)

Core Responsibilities

Primary Functions

  • Read, interpret, and apply complex engineering drawings, CAD files (SolidWorks, AutoCAD), and GD&T specifications to plan, machine, and assemble precision molds for injection molding, compression molding, and die casting, ensuring final parts meet dimensional and cosmetic tolerances.
  • Program and operate multi-axis CNC milling machines and lathes (Fanuc, Haas, Mazak), create or edit CAM programs (Mastercam, SolidCAM), and set up fixtures and tooling to produce mold components to exacting specifications and surface finishes.
  • Use electrical discharge machining (EDM) — both wire EDM and sinker EDM — to cut intricate cavities, cores, and features in steel and copper alloys, and optimize EDM parameters to minimize recast and maximize feature accuracy.
  • Perform fine detail hand fitting, polishing, and finishing of mold cavities and cores using stone, file, die grinder, and polishers to achieve required surface finishes, part release properties, and cosmetic quality.
  • Assemble, align, and test multi-cavity and family molds, install and connect cooling and heating circuits, valves, ejector systems, sliders, lifters, and other moving components while verifying clearances and functional movement.
  • Conduct mold trials and first-article/sample runs on injection molding machines to validate tool performance, iterate on gate locations, venting, cooling balance, and ejection systems, and collaborate with process engineers to optimize cycle times and part quality.
  • Troubleshoot production issues such as short shots, flash, burn marks, sink, warpage, and dimensional drift by diagnosing mold-related causes and performing corrective machining, polishing, or replacement of components.
  • Perform preventive maintenance and scheduled service on molds including cleaning, rust prevention, bushing replacement, surface treatment touch-ups, and inspection to extend tool life and maintain production readiness.
  • Repair damaged cores, cavities, inserts, and runner systems by welding (TIG/Brazing where appropriate), re-machining, replacing inserts, or fabricating new components while maintaining metallurgical and hardness requirements.
  • Measure complex parts and tooling features using precision instruments (micrometers, calipers, height gauges, profilometers) and program or operate coordinate measuring machines (CMM) to verify tolerances and generate inspection reports.
  • Manage tooling documentation, including bills of materials (BOM), maintenance logs, repair histories, setup sheets, mold drawings, and CAD revisions in PLM/ERP systems (SAP, Oracle, or equivalent) to ensure traceability and quick changeover.
  • Select appropriate tool steels, pre-hardened materials, coatings (PVD, nitriding), and secondary processes (heat treat, cryogenic treatment) based on part volume, material compatibility, and expected mold life, coordinating with heat-treat vendors as needed.
  • Balance and optimize hot runner systems and cold runner designs, perform flow analysis feedback to engineering, and modify gating and runner geometries to reduce cycle time, scrap, and downstream finishing operations.
  • Implement and document mold modifications and engineering change orders (ECOs) in partnership with design engineering to improve manufacturability, reduce cycle time, or address production failures.
  • Fabricate and install complex mechanical features such as slides, cams, lifters, and cam-driven mechanisms, ensuring synchronized action and longevity under high-cycle conditions.
  • Train, mentor, and provide technical guidance to apprentices, junior machinists, and molding technicians on best practices for mold maintenance, safe machine operation, and precision tooling techniques.
  • Apply root cause analysis and structured problem-solving (5 Whys, Fishbone) to recurring molding defects and mold failures, proposing long-term improvements and retrofit solutions.
  • Ensure compliance with plant safety protocols, lockout/tagout procedures, and PPE requirements while working with heavy tooling, hydraulic presses, and high-precision machinery.
  • Coordinate with purchasing, engineering, and suppliers to cost-effectively source spare parts, inserts, and specialty components while monitoring inventory levels of critical tooling consumables.
  • Drive continuous improvement initiatives in the tooling area by proposing process changes to reduce set-up time, improve first-time quality, and increase overall equipment effectiveness (OEE).
  • Prepare accurate time and cost estimates for mold repairs, modifications, and new builds; prioritize work based on production schedules and customer delivery requirements.
  • Maintain a clean, organized toolroom and secure storage for molds, following 5S principles and ensuring quick access and safe handling of heavy tooling.

Secondary Functions

  • Support production by prioritizing emergency mold repairs and quick-turn service to minimize downtime and meet customer deadlines.
  • Collaborate with quality and process engineering teams to create and update standard operating procedures (SOPs) and mold setup/checklist documentation.
  • Assist with tooling lifecycle planning, including retirement recommendations and capital planning input for new or replacement molds.
  • Participate in design reviews and prototype planning to advise on manufacturability, cost, and expected maintenance needs of new tooling designs.
  • Maintain accurate records of downtime causes and corrective actions taken, contributing data to continuous improvement and root-cause databases.
  • Provide input to buyer/vendor evaluations for specialized machining, heat treat, or coating suppliers and oversee outsourced work to ensure acceptance criteria are met.
  • Support lean manufacturing initiatives by identifying waste in set-up, repair, or storage processes and implementing countermeasures.
  • Work with safety and facilities teams to evaluate handling equipment (cranes, lifting fixtures) for safe mold movement and storage.
  • Help plan and execute mold conversions and changeovers on the production floor, including logistics, rigging, and alignment checks.
  • Participate in cross-functional troubleshooting calls with customers, suppliers, and production to rapidly resolve off-spec or urgent part issues.

Required Skills & Competencies

Hard Skills (Technical)

  • Advanced blueprint and CAD interpretation skills, including GD&T application and translating 2D/3D models into machining and assembly steps.
  • Proficient CNC programming and operation of milling machines and lathes (experience with Fanuc, Haas, Mazak controls preferred).
  • Experience authoring or editing CAM programs using Mastercam, SolidCAM, or equivalent CAM software to optimize toolpaths and cycle time.
  • Proficient in EDM operations (wire and sinker) including electrode fabrication, EDM parameter selection, and post-EDM finishing.
  • Skilled in precision grinding, honing, polishing, and finishing techniques for mold cavities and parting surfaces to meet cosmetic requirements.
  • Strong metrology capabilities: micrometers, calipers, height gauges, pin gages, surface profilometers, and CMM programming/operation.
  • Experience with injection molding fundamentals, hot runner systems, cold runners, gating design, and mold cooling/heating circuits.
  • Familiarity with tool steels, heat treat specifications, surface treatments/coatings, and hardness verification methods.
  • Practical experience with mold assembly, alignment, ejector systems, slides, lifters, core pulls, and hydraulic/pneumatic actuators.
  • Proficient with PLM/ERP and maintenance systems (SAP, Oracle, Maximo or similar) for documentation, BOMs, and work orders.
  • Welding and repair skills for mold repairs (TIG, brazing, or soft welding techniques) where applicable.
  • Ability to perform root cause analysis and implement corrective actions for tooling-related production issues.

Soft Skills

  • Meticulous attention to detail and commitment to precision in manufacturing and documentation.
  • Strong problem-solving and analytical thinking to diagnose complex mold and process issues quickly and effectively.
  • Effective verbal and written communication skills for cross-functional collaboration with engineers, production, and suppliers.
  • Time management and prioritization skills to balance emergency repairs with scheduled maintenance and projects.
  • Team player with an inclination to mentor junior staff and contribute to a culture of continuous improvement.
  • Adaptability and resilience to work in fast-paced production environments with shifting priorities.
  • Initiative and ownership of tooling lifecycle and performance metrics.
  • Safety-focused mindset with consistent adherence to lockout/tagout and other safety procedures.
  • Customer-service orientation when interacting with internal customers (production, quality, engineering) and external vendors.
  • Documentation discipline — ability to record and maintain traceable repair histories and setup instructions.

Education & Experience

Educational Background

Minimum Education:

  • High school diploma or GED with relevant vocational training or completion of a tool & die or machining apprenticeship program.

Preferred Education:

  • Associate degree or certificate in Tool & Die, Precision Machining, Manufacturing Technology, or Mechanical Engineering Technology.
  • Journeyman certification or equivalent trade qualification preferred.

Relevant Fields of Study:

  • Tool & Die Technology
  • Precision Machining / CNC Machining
  • Manufacturing Technology / Industrial Maintenance
  • Mechanical Engineering Technology

Experience Requirements

Typical Experience Range: 3–10 years of hands-on mold making, toolroom, or precision machining experience.

Preferred: 5+ years of direct mold-making experience including CNC machining, EDM, mold assembly, and production troubleshooting in injection molding or die casting environments.

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