Open to opportunities

John Reynolds

@johnreynolds

Manufacturing engineer specializing in aerospace and medical-device plastics, driving quality, process validation, and production readiness.

United States

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What I'm looking for

I seek roles where I can lead NPI-to-production process development, validation, and continuous improvement in regulated industries, mentoring teams and ensuring product compliance.

I am a plastics-focused manufacturing engineer with deep experience in aerospace and medical device production, process development, and quality systems. I combine hands-on engineering with documentation and validation expertise to bring products from NPI to robust production.

At Tri‑Mack I led NPI-to-production project management, created manufacturing documents, designed fixturing, and ensured customer specification compliance. At MW Components I executed IQ/OQ/PQ protocols, led APQP events, and mentored junior engineers on PPAP and validation.

Currently at Raytheon (via managed staffing) I develop manufacturing data packages for assemblies using adhesive bonding, soldering, grit blasting and more, disposition nonconforming material, and support floor troubleshooting and method-sheet creation.

I hold a B.S. and M.S. in Plastics Engineering from UMass Lowell and am named on a U.S. patent for a composite polymeric EMI‑shielding material. I focus on root-cause problem solving, continuous improvement, and translating regulatory and customer requirements into effective manufacturing practice.

Experience

Work history, roles, and key accomplishments

Current

Manufacturing Engineer

Current

Raytheon

Jan 2025 - Present (1 year)

Developed process manufacturing data packages for assemblies involving adhesive bonding, soldering, and grit blasting; dispositioned non-conforming material and implemented root-cause corrective actions to improve assembly yield and reliability.

Process Development Root Cause Analysis Rework Documentation Troubleshooting

Manufacturing Engineer / Project Engineer

Tri-Mack Plastics Manufacturing

Aug 2021 - Oct 2024 (3 years 2 months)

Created manufacturing documentation and inspection plans, designed fixturing for bonding and grit blasting, and led NPI-to-production projects ensuring compliance with aerospace customer specifications.

PFMEA Aerospace Manufacturing

Manufacturing / Engineering Manager

MW Components

Jan 2019 - Jun 2021 (2 years 5 months)

Managed engineering team and led APQP, PPAP, and IQ/OQ/PQ activities for medical device injection molding; drove root-cause investigations and implemented ECNs and continuous improvement initiatives.

APQP Injection Molding Root Cause Analysis ECN Mentoring

Manufacturing Engineer

MW Components

Feb 2012 - Jan 2019 (6 years 11 months)

Executed process development and validation for injection-molded medical components, performed DOE to optimize process windows, and prepared PFMEA and process flow documentation for PPAP submissions.

Injection Molding PFMEA Process Flow Testing

Education

Degrees, certifications, and relevant coursework

University of Massachusetts Lowell

Bachelor of Science, Plastics Engineering

Completed a Bachelor of Science in Plastics Engineering focusing on polymer processing and manufacturing principles relevant to aerospace and medical device industries.

University of Massachusetts Lowell

Master of Science, Plastics Engineering

Completed a Master of Science in Plastics Engineering with advanced study in polymer materials, molding processes, and validation methods for regulated industries.