Job Description

Job Title : Design Engineer

Location : DeKalb, IL

Type: Direct Hire / Full time.

Pay + Benefits.

Job Description :

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 the successful commercialization of products.

Duties:

• Design thermoformed packaging products from concept through production using CAD software (e.g., SolidWorks).
• 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.

Required:

• 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 (SolidWorks 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.

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