Robert J. Kelley




Plastic & Rubber Mold Design (2D/3D)

Plastic Part Design (3D)

Electro/Mechanical Drafting (2D)


CAD Programs

SolidWorks (2D/3D)

Cimatron (Mold design package) (2D/3D)

Pro/E (Mold design package w/EMX) (2D/3D)

AutoDesk Inventor / AutoCAD Mechanical (2D/3D)

SolidEdge ST2 (2D/3D)





Roehr Tool Corp., Hudson, MA

(September 2011 to Present)

Design Engineer

Working in SolidWorks. Taking applications from customers to see if Roehr Tool products (RT, DT Collapsible cores, and ExCav expandable cores) will work with them, including customizing Roehr Tool's standard style cores to get the customers designs to work with either minimal or no design changes. Quote them if applicable. Design applicable cores for customers, complete mold designs, retro fit collapsible core into existing molds using competitors cores or unscrewing molds, and design multi-cavity/part interchangeable molds. Streamline the design process for the cores in 3D and manufacturing drawings in 2D. Product sizes range from 11mm diameter up to 9" threads. Wide range of industries serviced.


Precision Tool And Die, Derry, NH

(July 2010 to September 2011)

Mold Designer

Working in Creo/Pro with EMX 6 and SolidWorks 2011 with MoldWorks. Working on single cavity proto-type mold to multi-cavity production molds for medical and consumer goods industries. Also some product design for the medical industry. Working in 3D design with some 2D detailing.


Trelleborg Sealing Solutions U.S., Inc., Somersworth, NH

(March 2009 to June 2010)

Tooling Engineer

Currently working in SolidEdge ST designing/detailing compression molds, trim dies, and loading/knock-out boards for rubber diaphragms and lip seals in 2D and 3D. Anything from single cavity Proto-type to multi-cavity production molds. Industries currently supported are the aerospace, industrial, and consumer goods.


RJK Ltd., Leominster, MA

(June 2007 to March 2009)

Sr. Mold Designer

Currently working in Cimatron E8.5 designing/detailing molds for the plastic and rubber industries in 3D and 2D. Anything from single cavity Proto-type to multi-cavity production molds. Industries currently supported are the automotive, medical, and consumer goods industries.


Precision Tool And Die, Derry, NH

(October 2002 to May 2007)

Mold Designer

Working in Pro/E Wildfire 3, utilizing the EMX 4.1 package. Working on single cavity proto-type molds to multi-cavity production molds for the medical and consumer goods industries. Working in 3D design with some 2D detailing.


StanCast, Inc., Leominster, MA

(February 1997 to October 2002)

Mold Designer

Worked with customers translating 3D CAD databases from their systems into ProEngineer. Then create 3D mold splits and electrodes in ProEngineer for use by MasterCAM for manufacturing. Also create 2D drawings in ProEngineer for use in AutoCAD for the preliminary and final layout presented to the customer and 2D details for the shop floor.


Worked on single cavity proto-type to multi-cavity production plastic injection molds, including hot drop nozzles to sequential valve gate systems for the automotive, medical, and consumer markets.


Professional History prior to February 1997

Since July 1979 I have worked my way thru electro/mechanical drafting, machine design/drafting, part design/drafting, and mold design/drafting jobs. By way of permanent and contract positions in the computer, automotive, medical, and consumer goods industries. I've used various CAD systems (Unigraphics, ProEngineer, AutoCAD, Cadkey, Cadra, and ME10) over the years and have working knowledge of other CAD systems.




Over the years I have taken several college courses at Northeastern University, Wentworth Institute of Technology, Worcester Polytechnic Institute, Middlesex Community College, Nypro Institute, and the University of Lowell.


The courses include: Mechanics A, Algebra I and II, Pre-calculus, Technical math, English I, Drafting, Injection molding, Statistical quality control, Blueprint reading, Mold design, Moldflow, AutoCAD, ProEngineer basic, ProEngineer mold design, ProEngineer fundamentals of drawing and Cimatron.


Robert E. Kelley



Extensive experience in the rubber molding industry; in Tool Engineering and Project Engineering capacities. Automotive industry experience. Strengths in tool and mold design, tool upgrades/revisions, interfacing/managing outside tool programs and vendors, scrap and reject reduction. Experience with injection, compression, transfer, hot and cold runner injection molds. Have managed mold shop operations. Solid interpersonal skills.





Sr. Tooling Engineer

(January 2006 to Present)
RJK Ltd., Leominster, MA

Liaison with customers to finalize mold design for optimum performance.

Tooling Engineer

(January 1997 to December 2005)
ITW Southland Technologies, Virginia Beach, VA
Responsible for all mold design for elastomeric components for the automotive and custom molded products groups. Majority of tooling is double deck - cold runner molds. Oversee mold shop operations.

Project Engineer

(October 1992 to December 1996)
Wirtz Manufacturing Company, Inc., Port Huron, MI
Headed design group for design of molds for elastomeric products for various customers; including Southland Technologies, Plumley Companies, Cooper Engineered Products, Ames-Avon Industries, and various smaller companies. Mold designs were compression, transfer, hot runner and cold runner injection molds.

Corporate Tooling Engineer

(September 1990 to October 1992)
L.C.I. (Lexington Components, Inc.), Warren, OH
Responsible for the company mold design and tool shop for elastomeric components to the automotive and medical industries. Moved machine shop from South Carolina to Ohio; re-manned to a (3) three shift operation. Established apprenticeship program. Member of an engineering group in the study and implementation of waste less/flash less/vacuum molding program.

Development Engineering/Project Engineer

(March 1989 to September 1990)
Goodyear Tire & Rubber Company, Lincoln, NE
Responsible for all tooling for the injection molding of automotive air duct hosing. Converted new tooling manufacture from cast cavities to machined cavities where feasible. Reduced reject rate at press from 15% in March 1989 to 5% in March 1990.

Director, Tool and Die

(February 1985 to February 1989)
Southland Industries, Inc., Virginia Beach, VA
Established new tool & die shop operation. Bought all equipment and hired all shop personnel. Established new production machining operation for automotive rocker covers. Designed molds for the injection molding of automotive gaskets, rocker cover, oil pan, and end seals. Majority of molds were cols runner design.

Engineering Manager

(May 1980 to February 1985)
John Crane - Houdaille, Inc., Vandalia, IL
Responsible for all engineering disciplines for custom molding operations; as well as the tool and sample shops. Injection molding, compression, and transfer molding operations. Reduced scrap from 10% to 2% in (4) four years. Established new mold vendor base.

Manager, Mold Engineering

(May 1978 to April 1980)
Desma Industrial Machines, West Acton, MA
Responsible for turnkey mold design. Worked with sale in presentations to potential customers. Designed new tooling or converted existing tooling to run trials in our demo area. Designed injection molds for customers. Established mold vendor base for turnkey tooling packages.

Professional History prior to May 1978

Antioch/Chicago, IL
Worked as a consultant/mold designer for various mold/tool shops in the rubber industry. Designed mold for compression, transfer, and injection process. Liaison for manufacturers with shops for repairs/revisions required to upgrade/restore tooling. For many years, was President of Ace Mold Company in Chicago, IL.




Tool & Die Apprentice Program - Chicago, IL

Additional courses in mechanical drafting and accounting

Currently use AutoCAD 2009 Mechanical



RJK Ltd. 37C Meadow Pond Drive Leominster, MA 01453 Office (978) 537-4660 -- Cell (978) 235-5581