Senior Design Engineer - Mining Consumables Tooling

Senior Engineer

Senior Design Engineer – Rubber & Polyurethane Tooling

Do you want to help shape a more sustainable future in mining?

At FLS, our MissionZero ambition is focused on enabling zero-emissions mining. Through innovation, engineering excellence, and deep industry expertise, we help our customers produce the materials needed for the world’s progress—responsibly, efficiently, and sustainably.

Important – Specialist Experience Required

This is a specialist tooling design role and requires direct, hands-on experience designing rubber and/or polyurethane moulds and tooling.

To be considered, you must have proven experience in one or more of the following:

• Rubber mould design

• Polyurethane tooling design

• Injection mould tooling

• Open-cast polyurethane mould systems
  

Candidates without direct rubber or polyurethane tooling/mould design experience will not be shortlisted.

We are seeking a technically strong, detail-oriented, and driven engineer to join our global Mining Products Engineering Department. This role is ideal for someone who enjoys solving complex design challenges, developing specialised tooling for high-performance consumables, and contributing to product innovation across a global mining portfolio.

About the Role

As part of our Screens & Trommels Consumables Engineering team, you will focus on the design and development of tooling for injection-moulded rubber and open-cast polyurethane consumables used across FLS mining product lines.

This is a hands-on engineering role with strong collaboration across global engineering, manufacturing, R&D, and product line teams. You will play a critical role in converting product requirements into robust, manufacturable tooling solutions that deliver performance, repeatability, and quality at scale.

Key Responsibilities

• Design and develop tooling for rubber screening media, polyurethane screening panels, rubber moulds, and polyurethane panel tooling

• Interpret and apply engineering drawings, product specifications, and material requirements to create accurate and manufacturable tooling designs

• Execute detailed design work in SolidWorks, AutoCAD, and Enovia, including 3D models, layouts, manufacturing drawings, and revision control

• Develop complete tooling packages for injection moulding and open-cast polyurethane moulding, including:

  • 3D models

  • detailed manufacturing drawings

  • machining files

  • bills of materials (BOMs)

• Translate product concepts into complete technical documentation and production-ready tooling designs

• Ensure designs account for:

  • manufacturability

  • tolerances

  • curing requirements

  • material flow

  • shrinkage behaviour

  • tooling durability

• Work closely with manufacturing teams to support:

  • tooling trials

  • process optimisation

  • troubleshooting

  • continuous improvement initiatives

• Optimise existing mould and tooling designs based on:

  • wear performance

  • production issues

  • field feedback

  • quality outcomes

• Identify design and manufacturing risks early and implement practical, robust engineering solutions

• Maintain CAD libraries, tooling databases, and revision controls to ensure traceability and data accuracy

• Contribute to the development and improvement of global tooling, drawing, and CAD standards

• Stay current with advances in tooling methods, elastomer materials, moulding technology, and engineering systems to support ongoing innovation

What You Bring

Critical Experience (Non-Negotiable)

This is not a general mechanical design role.

To be successful in this position, you must have direct, hands-on experience designing rubber and/or polyurethane tooling or moulds, including experience in one or more of the following:

• Rubber mould design

• Polyurethane mould/tooling design

• Injection mould tooling for elastomeric products

• Open-cast polyurethane moulding systems

Qualifications & Technical Capability

• Bachelor’s degree in Mechanical Engineering, Design Engineering, or equivalent

• Minimum 5 years’ experience in design engineering within consumables, mining, heavy industrial, or manufacturing environments

• Strong proficiency in:

  • SolidWorks (3D modelling and drafting)

  • AutoCAD (2D detailed drawings)

  • Enovia (PLM – web and Windows clients)

  • ANSYS or similar analysis/simulation tools

• Strong understanding of:

  • engineering fundamentals

  • rubber and polyurethane material behaviour

  • moulding and tooling principles

  • manufacturing methods and workflows

  • tolerancing and production documentation

Personal & Professional Attributes

• High attention to detail and strong commitment to engineering quality

• Strong problem-solving capability with a practical, hands-on mindset

• Ability to manage multiple projects and priorities in a structured way

• Strong written and verbal communication skills in English

• Ability to collaborate effectively across global, cross-functional teams

• Continuous improvement mindset with a focus on performance, reliability, and manufacturability

Why Join FLS

At FLS, you’ll be part of a global engineering business solving real-world challenges in mining and sustainability. This role offers the opportunity to apply specialist tooling expertise in a high-impact environment where your work directly supports product performance, manufacturing excellence, and our broader MissionZero ambition.

What We Offer

• Competitive benefits package including:

  • Health Insurance

  • Personal Accident / Disability cover

  • Group Term Life Insurance

  • Annual health check-up

  • Voluntary insurance options

• 30 days paid time off, with up to 10 days carried forward as earned leave

• Flexible work arrangements to support work-life balance

• Financial support for continuing education and professional development

• Employee Assistance Program

• Access to a global network of colleagues, technical experts, and career growth opportunities

Inclusion & Equal Opportunity

We believe diversity strengthens our business. FLS is committed to creating an inclusive workplace where people of all backgrounds and perspectives can thrive.

As an equal opportunity employer, we encourage applications from all qualified candidates. To support fair and unbiased recruitment, please exclude personal information such as age, ethnicity, marital status, number of children, and photographs from your application materials.

Experience Level

Senior Level