Title: Design Engineer - Thermoformed Packaging

Design Engineer – Thermoformed Packaging

Location: DeKalb, IL (100% Onsite) Type: Full-Time Travel: Up to 20%

About the Role

We are seeking a creative and technically strong Design Engineer with hands-on experience in thermoformed packaging for retail and food markets. This engineer will play a key role in transforming customer requirements into manufacturable packaging solutions by designing components, developing tooling, collaborating with cross-functional teams, and driving product commercialization from concept through production.

This role is ideal for someone who enjoys designing packaging that is functional, manufacturable, and visually appealing — and who thrives in a fast-paced, engineering-driven environment.

Key Responsibilities

Packaging & Product Design

• Design thermoformed packaging from concept through production using SolidWorks or similar CAD tools.
• Develop detailed 3D models, assemblies, and 2D manufacturing drawings.
• Translate customer requirements into innovative, practical packaging solutions.
• Conduct feasibility studies, including draft analysis, stackability, material selection, and structural integrity reviews.

Tooling & Prototyping

• Design thermoform production tooling and seal tooling for efficient, high-quality manufacturing.
• Partner closely with tooling engineering teams to ensure tooling aligns with production requirements.
• Use 3D scanning and 3D printing as needed for prototyping and rapid iteration.
• Support prototype builds, testing, and design validation activities.

Cross-Functional Collaboration

• Work with sales, project managers, and manufacturing teams to ensure designs meet customer, quality, and production goals.
• Participate in customer discussions to gather requirements and present design concepts.
• Identify and mitigate design, material, or process risks early in the project lifecycle.
• Maintain accurate documentation and manage design revisions through PDM/PLM systems.

Innovation & Continuous Improvement

• Stay current with new materials, design technologies, and industry trends in thermoforming.
• Incorporate sustainability and cost-efficiency into packaging designs.
• Improve design workflows and identify opportunities to enhance manufacturing performance.

Required Qualifications

• Bachelor's degree in Industrial Design, Mechanical Engineering, Packaging Engineering, or related field.
• 2+ years of packaging design experience, specifically in thermoforming or plastics packaging.
• Proficiency in SolidWorks (strongly preferred).
• Expertise in thin-gauge thermoforming design, including: draft angles, wall thickness standards, undercuts and formability considerations.
• Knowledge of PET, HIPS, PVC, and similar plastic materials.
• Familiarity with production tooling processes and manufacturing constraints.
• Ability to identify and resolve design risks proactively.
• Strong communication skills and collaboration abilities.
• Ability to handle multiple projects and deadlines in a fast-paced environment.

Preferred Experience

• Experience coordinating packaging development directly with customers.
• Hands-on exposure to thermoforming equipment or tooling shops.
• Understanding of sustainability requirements in packaging.

Ideal Candidate Profile

You are a detail-oriented, highly creative design engineer who understands the nuances of thermoformed packaging and enjoys working hands-on with tooling, prototypes, and cross-functional teams. You thrive in an environment where design excellence, manufacturability, and customer needs intersect — and you are excited about contributing to packaging solutions used by major retail and food brands.

Interview Process

1. 30-minute conversation with a recruiter
2. 1-hour video interview with hiring manager
3. Panel interview with engineering team (may include onsite visit)

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