Design Engineer – Thermoformed Packaging

Design Engineer – Thermoformed Packaging Base pay range

$85,000.00/yr - $/yr

Location: DeKalb, IL (100% Onsite)

Type: Full-Time

Travel: Up to 20%

Salary Range: $85,000–$100,000

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.

• Design thermoformed packaging from concept through production using Solid Works 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.

• 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.

• 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.
• 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.

• 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 Solid Works (strongly preferred).
• Expertise in thin‑gauge thermoforming design, including:
• 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.

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

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.

• 30‑minute conversation with a recruiter
• 1‑hour video interview with hiring manager
• Panel interview with engineering team (may include onsite visit)

Associate

Full-time

Engineering and Manufacturing

Engineering Services, Plastics Manufacturing, and Manufacturing