Work Preference
Summary
Overview
Work History
Education
Skills
Websites
Accomplishments
Work Availability
Languages
Software
Certification
Languages
Portfolio
Timeline
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Marcelo Nicosia
Open To Work

Marcelo Nicosia

Sr. Mold Designer
Oak Park,IL

Work Preference

Job Search Status

Open to work
Desired start date: Open to discussion

Desired Job Title

Mold designer

Work Type

Part TimeContract WorkGig WorkConsulting

Location Preference

On-SiteRemoteHybrid
Location: Oak Park, IL, USMiami, FLFort Myers, FLTampa, FLChicago, IL
Open to relocation: Yes

Salary Range

$0/hr - $1000/hr

Important To Me

Flexible work hoursWork from home optionWork-life balanceTeam Building / Company Retreats

Summary

Dynamic Mechanical Engineer boasting over 30 years of expertise in designing high-precision tooling for injection molding, thermoset, and die-cast applications. Expert in advanced CAD systems, practical toolmaking, and pioneering product development skills. Demonstrated leadership in design initiatives from concept to production, ensuring technical solutions align with client and manufacturing needs. Combining a strong technical education with a robust understanding of manufacturing processes and tooling principles, I provide dependable, cost-efficient solutions that are timely, and within budget.

Overview

37
37
years of professional experience
7
7
Certifications

Work History

Sr. Mold Designer

Isometrix Design Inc.
Oak Park
02.2001 - Current
  • Established and directed an engineering firm, providing innovative tooling and product development solutions across diverse industries.
  • Engineered complex molds and tooling with advanced CAD tools, generating fully detailed 3D tooling, superstructures, and entirely parametric assembly models and drawings.
  • Expertise in advanced molding technologies encompasses co-injection, overmolding, gas assist, dissolvable core, insert molding, micromolding, stack molds, unscrewing mechanisms, multi-slide/stage systems, Windage molding, and Metal Injection Molding.
  • Developed products for automotive, medical, consumer goods, packaging, electronics, military, and hardware applications.
  • Applied expertise in high-performance engineered materials such as phenolic, PEEK, TPU, LSR, LCP, and related polymers.
  • Directed DFM, mold feasibility, and mold flow/cooling analyses, resulting in up to 20% reduction in cycle time and enhanced part quality.
  • Worked alongside design and manufacturing teams to cut mold production costs by nearly 15%.
  • Implemented CAD automation, refined surfacing techniques, and created custom API tools, elevating design efficiency by up to 20%.
  • Managed multiple concurrent projects while consistently achieving schedule, budget, and quality targets.
  • Created internal error-detection protocols that lowered design-phase errors by up to 15%
  • Compiled and preserved mold design documentation, integrating tolerance drawings and BOMs.
  • Conducted accurate handling of suitable metrology tools for successful reverse engineering.
  • Evaluated industry best practices, integrating strategies into design processes, enhancing company reputation as a leader in tooling engineering services.
  • Engaged directly with OEMs, startups, and suppliers, delivering tooling strategy, supplier qualification, and customer-facing technical leadership that secured repeat business.

Sr. Mold Designer

Courtesy Corp. (Flex)
Buffalo Grove
03.1996 - 02.2001
  • Designed high-cavitation molds for medical and cosmetic packaging applications.
  • Engineered complex mechanisms, including stack, rack-and-pinion lifts, and motorized unscrewing systems.
  • Developed complete mold design documentation, including drawings and bills of materials.
  • Contributed to advanced cooling strategies for stack molds, enhancing cycle times by 12%.
  • Applied innovative solutions for thread stripping, living hinge, and tamper-evident features.
  • Served as liaison among Product Engineering, Marketing, and Manufacturing teams.
  • Authored Mold Design Guidelines to standardize and streamline design practices.
  • Created CAD-based mold-splitting methodology adopted as departmental standard.

Mold Maker, Mold Designer

Richard Schultz Co.
Elmwood Park
02.1989 - 03.1996
  • Engineered and manufactured tooling for injection molding and die-casting operations.
  • Designed and assembled large-scale tools and dies for automotive, aerospace, mining, military, and government programs.
  • Developed production of advanced molds for structural and aesthetic components, encompassing automotive bumpers, dashboards, door panels, engine blocks, transmission cases, turbine propellers, agricultural devices, and large consumer items.
  • Executed advanced incremental CNC programming technique to manufacture high-precision paper extrusion dies, achieving 30% reduction in machining time.
  • Managed and executed programming of CNC milling and precision machining equipment to deliver tooling to exact specifications.
  • Promoted to Mold Maker after completing Journeyman Apprenticeship and receiving TMA certifications.

Education

Engineering Technology/Cad Advanced Certificate - Honor Roll

Triton College
River Grove, IL
11-1997

Mechanical Engineering - Matricería Y Automotríz.

Universidad De Buenos Aires
Argentina
11.1988

Skills

  • SolidWorks CSWA, Cadkey, and Rhino
  • Mold design: injection, compression, thermoset, silicone, and rubber
  • Tool design: die casting, trimming, extrusion, transfer, and vacuum forming
  • Manufacturing processes: mold making and CNC programming/machining
  • Materials: steel, aluminum, cast iron, alloys, thermoplastic, thermoset, and composites
  • Product design: medical, consumer goods, closures, connectors, military, defense, sporting goods, and POP systems development
  • Project management: planning, quoting, execution, review, and documentation
  • Problem-solving: analysis, troubleshooting, and remediation
  • Teamwork: collaborative and team-oriented

Websites

Accomplishments

  • Founded and led a Pioneering Design Engineering firm that successfully supported the manufacturing needs of OEMs, molders, and mold builders for over 25 years.
  • Built and led teams of top design engineers, aligning technical execution with project objectives and long-term client partnerships.
  • Successfully delivered engineering solutions for 100+ clients, supporting product development, and tooling performance.
  • Earned repeat contractual engagements with leading OEMs including Honeywell, Motorola, Weber, Tesla, GE, Molex, Harley-Davidson, Kohler, Kimberly-Clark, Abbott, Baxter, P&G, AT&T, Revlon, ITW, Dana, Eaton, and others across automotive, medical, consumer, and industrial markets.

Work Availability

monday
tuesday
wednesday
thursday
friday
saturday
sunday
morning
afternoon
evening
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Languages

  • Spanish
  • English
  • Spanish

Software

Solidworks

Cadkey

Rhino

Certification

CATI Certified SolidWorks Associate CSWA certificate 2002

Languages

English
Native language

Portfolio

FEATURED
Featured Picture
complex surfacing
Featured Picture
die cast tool
Featured Picture
injection mold
Featured Picture
conceptual product design
Featured Picture
drawing and tolerancing

Timeline

Sr. Mold Designer

Isometrix Design Inc.
02.2001 - Current

Sr. Mold Designer

Courtesy Corp. (Flex)
03.1996 - 02.2001

Mold Maker, Mold Designer

Richard Schultz Co.
02.1989 - 03.1996

Engineering Technology/Cad Advanced Certificate - Honor Roll

Triton College

Mechanical Engineering - Matricería Y Automotríz.

Universidad De Buenos Aires

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