Thermoforming Process Technician

Job Description

Job Description

THERMOFORMING PROCESS TECHNICIAN

Department: Manufacturing / Operations    Reports to: Manufacturing / Operations Manager    Classification: Full-Time

POSITION SUMMARY

The Thermoforming Process Technician is a hands-on technical specialist responsible for developing, troubleshooting, optimizing, and standardizing heavy-gauge single-sheet and twin-sheet thermoforming processes. The role supports thermoplastic sheet applications typically ranging from 1 mm to 5 mm and greater, assesses tooling and manufacturing feasibility, contributes technical assumptions to new and existing project quotations, and helps deliver safe, consistent quality, cost, and production performance.

ESSENTIAL RESPONSIBILITIES

·   Troubleshoot forming defects and process variation, including webbing, thinning, bridging, incomplete forming, warpage, heating or cooling inconsistencies, and twin-sheet bonding/alignment issues.

·   Adjust and validate heating profiles, vacuum/pressure, forming sequence, plug assist, cooling, and cycle times; establish repeatable process settings and support production startup.

·   Evaluate mold and fixture designs for draft, material distribution, venting, cooling, part release, alignment, manufacturability, and process reliability; recommend improvements.

·   Review CNC trim and assembly fixtures; collaborate with internal teams and external tooling suppliers to resolve tooling issues and support trials.

·   Support new-product introduction, prototypes, first-article builds, and process validation by reviewing drawings, CAD data, specifications, materials, and production risks.

·   Provide technical input for quotes and requotes, including sheet utilization, material requirements, expected scrap, cycle times, tooling, labor, secondary operations, capacity, and manufacturing assumptions.

·   Partner with Production, Engineering, Quality, Maintenance, Planning, Purchasing, and Commercial teams on technical problem solving and achievable manufacturing plans.

·   Drive sustained improvements in process capability, safety, scrap, material utilization, throughput, and cycle time using structured root-cause analysis and practical corrective action.

·   Develop and maintain setup sheets, process parameters, troubleshooting guides, and work instructions; train operators and share technical knowledge across shifts.

ROLE ACCOUNTABILITY

Acts as a technical process resource and recommends validated process or tooling changes. Production leadership retains accountability for daily staffing, scheduling, and production execution; commercial leadership retains final quote approval.

REQUIRED QUALIFICATIONS

·   Demonstrated hands-on experience with heavy-gauge thermoforming and strong knowledge of single-sheet processes; experience with twin-sheet forming strongly valued.

·   Proven ability to diagnose forming defects, evaluate processing conditions, and implement repeatable technical solutions.

·   Working knowledge of mold/fixture functionality, thermoplastic material behavior, machine systems, and manufacturing safety.

·   Ability to interpret engineering drawings, specifications, and technical data; communicate effectively across functions and document process standards.

PREFERRED QUALIFICATIONS

·   Three or more years of relevant thermoforming/process experience, or equivalent demonstrated expertise.

·   Experience with twin-sheet forming, CAD viewing, CNC trimming, trim fixtures, and new-product introduction.

·   Experience supporting RFQ technical reviews, manufacturing estimates, material utilization, and costing assumptions.

·   Experience with engineering-grade thermoplastics, regulated manufacturing environments, ERP systems, and Lean/Kaizen methods.

MEASURES OF SUCCESS

·   Stable, documented processes and fewer recurring defects or unplanned adjustments.

·   Reduced scrap and improved material yield, cycle time, and production efficiency.

·   Early identification of tooling/manufacturing risks and effective support of successful product launches.

·   Accurate and timely technical input to quotes and stronger operator capability through training and standard work.

WORK ENVIRONMENT & PHYSICAL REQUIREMENTS

Work is performed primarily in a manufacturing environment near heated machinery, tooling, and moving equipment. Requires regular standing, walking, equipment inspection, and occasional material/fixture handling within established safety limits. Appropriate personal protective equipment is required. Reasonable accommodation may be made to enable qualified individuals to perform essential job functions.

POSITION PURPOSE

Solve today’s process issues in ways that prevent their recurrence: understand the root cause, verify improvement, establish the standard, and transfer the knowledge to the production team.

Plastics Company that makes aerospace parts, reusable storage containers, dimple sheets for flooring.

Company Description

Plastics Company that makes aerospace parts, reusable storage containers, dimple sheets for flooring.