Extrusion Die & Tooling Designer

Job Summary

We are seeking a skilled Extrusion Die & Tooling Designer to design, develop, and continuously improve the extrusion dies, calibrators, and downstream tooling used to manufacture our PVC vinyl fence & railing profiles. This role will own tooling design from concept through commissioning, translating product drawings into robust, manufacturable tooling that runs at target rates, holds tight dimensional tolerances, and delivers a consistent surface finish.

The Die & Tooling Designer will also create standards tooling across the organization, upkeep, handling, & cleaning procedures, and will be responsible for tunning across the organization and partner closely with Production, Quality, and Product Development to launch new profiles, & resolve tooling-related defects. This individual will also manage outside toolmakers and maintain the tooling drawing and revision library for the facility.

Job Location

This position is onsite and can be based out of our Bulls Gap, TN, Dover, DE or Brooksville FL vinyl fence manufacturing facilities.

Job Responsibilities

Die & Tooling Design

• Design profile extrusion dies, including flow channels, land lengths, and die plates, for rigid PVC fence posts, rails, pickets, caps, and accessory profiles.
• Design calibrators/sizers, vacuum tanks, cooling fixtures, puller pads, and cutter/punch tooling to match profile geometry and line speed.
• Design co-extrusion and capstock feed systems to achieve uniform cap layer thickness and weatherable surfaces.
• Apply flow balancing, drawdown, swell, and shrinkage allowances to hit nominal dimensions and wall thickness with minimal tuning.

New Product & Profile Development

• Translate product drawings and customer requirements into complete die and calibration tooling packages.
• Review new profile designs for manufacturability and recommend geometry changes to improve extrudability, rate, and cost.
• Lead tooling trials and commissioning of new dies with Die Tuners and Production, documenting results and design iterations.

Tooling Performance & Continuous Improvement

• Die Tunning
• Analyze tooling-related defects (dimensional drift, warp, bow, die lines, gloss variation, wall thickness variation) and implement design corrections.
• Drive improvements in line speed, scrap rate, changeover time, and tooling life through design upgrades and standardization.
• Evaluate die steels, coatings, and surface treatments to improve durability and surface finish.

Supplier & Toolroom Management

• Manage external die shops and toolmakers: prepare RFQs, review quotes, approve designs, track lead times, and inspect incoming tooling.
• Provide machining guidance to the in-house toolroom for modifications, rework, and repairs (CNC, EDM, polishing).

Documentation & Standards

• Maintain 3D models, 2D drawings, bills of material, and revision control for all dies and tooling.
• Develop tooling standards, design guidelines, and setup sheets in partnership with Die Tuners and Process Engineering.
• Support quality and compliance requirements, including ASTM F964 and customer specifications for PVC fence profiles.

Safety & Collaboration

• Ensure tooling designs incorporate safe handling, lifting, and changeover practices.
• Partner with Manufacturing, Maintenance, Quality, and Product Development teams to ensure tooling supports business goals.
• Perform other related duties as assigned.

Job Requirements

• Bachelor’s degree in Mechanical, Plastics, or Manufacturing Engineering, or equivalent combination of education and hands-on experience.
• 5 plus years of experience designing profile extrusion dies and tooling, preferably for rigid PVC (vinyl) fence, railing, siding, decking, or window profiles.
• Proficiency in 3D CAD (SolidWorks or equivalent) and 2D drafting, including GD&T.
• Strong understanding of polymer flow, rheology, die balancing, and calibration/cooling principles; experience with die flow simulation software is a plus.
• Working knowledge of machining processes used in toolmaking (CNC milling, wire/sinker EDM, grinding, polishing).
• Experience with co-extrusion and capstock systems preferred.
• Strong analytical, problem-solving, and communication skills; able to work hands-on at the extrusion line.
• Ability to travel up to 35% to suppliers and sister facilities.