What are the responsibilities and job description for the Design Engineer – Thermoformed Packaging position at ThreePDS Inc.?
⭐ Job Title: Design Engineer – Thermoformed Packaging
Location: DeKalb, IL (100% Onsite)
Type: Full-Time
Travel: Up to 20%
Salary Range: $85,000–$100,000
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
- 30-minute conversation with a recruiter
- 1-hour video interview with hiring manager
- Panel interview with engineering team (may include onsite visit)
Salary : $85,000 - $100,000