Packaging Design Engineer

Base pay range: $85,000.00/yr - $/yr

Job Title: Packaging Design Engineer
Location: DeKalb, IL
Type: Direct Hire/Permanent

The Design Engineer will lead the design and development of thermoformed packaging products, transforming customer requirements into manufacturable, high-performance packaging solutions. This role emphasizes creative product design, tooling design, cross‑functional collaboration, and risk mitigation to ensure successful commercialization of products.

• Design thermoformed packaging products from concept through production using CAD software (e.g., Solid Works).
• Translate customer specifications and performance requirements into innovative packaging designs.
• Develop detailed 3D models, assemblies, and 2D drawings for packaging products.
• Design and develop production thermoform tooling and seal tooling to support efficient, high‑quality manufacturing.
• Utilize 3D scanning and 3D printing technologies to support prototype development, design validation, and rapid iteration.
• Evaluate and select materials aligned with performance, sustainability, and cost objectives.
• Conduct design feasibility studies, including draft analysis, stackability, and structural integrity of thermoformed parts.
• Collaborate with sales, project management, and manufacturing teams to ensure product and tooling designs are practical, efficient, and manufacturable.
• Collaborate closely with Tool Design Engineering to develop a comprehensive understanding of production tooling requirements and capabilities, and cross‑train to support integrated design‑to‑tooling solutions.
• Participate in customer meetings to understand needs, present design concepts, and refine solutions.
• Support prototype development and validation, including coordinating sample production and testing.
• Identify potential design, material, or process risks early in the project lifecycle, and proactively develop solutions to mitigate these risks through critical thinking and effective communication.
• Ensure designs comply with industry standards, customer requirements, and regulatory guidelines relevant to food and retail packaging.
• Maintain organized, accurate design documentation and manage design revisions through PDM/PLM systems.
• Stay current with new materials, design trends, and technologies relevant to the thermoformed packaging industry.

• Bachelor’s degree in Industrial Design, Mechanical Engineering, Packaging Engineering, or related field.
• 2+ years of experience in packaging design, preferably thermoformed or plastic packaging.
• Proficiency with 3D CAD software (Solid Works strongly preferred).
• Strong knowledge of design principles for thin‑gauge thermoformed packaging, including draft angles, wall thickness, and undercuts.
• Understanding of material properties relevant to PET, HIPS, PVC, or similar plastics.
• Familiarity with production tooling processes, with the ability to integrate packaging and tooling design considerations with manufacturing requirements.
• Ability to identify potential risks during design and commercialization phases, and develop effective mitigation strategies.
• Excellent problem‑solving and communication skills with an eye for design aesthetics and functionality.
• Ability to manage multiple projects and meet deadlines in a dynamic environment.

Location: DeKalb, IL – 100% onsite.

ESPO Corporation

630‑789‑2525

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Leaders in Technical Recruiting & Staffing since 1965

ESPO has a comprehensive benefit package which includes PTO, Group Health and Dental Insurance, 401(k).. etc after you have satisfied the necessary waiting periods.

We are an Equal Opportunity Employer and value the benefits of diversity in our workforce.

All qualified applicants will receive consideration for employment without regard to race, color, religion, gender, gender identity and expression, national origin, disability, protected Veteran status, or any other attribute or protected characteristic by law.