Flexible Sensor Design Engineer Jobs in Illinois

TOPPAN Packaging Americas specializes in designing and manufacturing sustainable, high-performance flexible and thermoformed packaging solutions for the food, beverage, medical and consumer goods industries. We offer products like transparent high barrier films, pouches, clamshells and trays, utilizing advanced technology to enhance product safety, visibility and environmental sustainability.

TOPPAN Packaging Americas operates as part of the global TOPPAN group, with 22 manufacturing facilities across North America, Latin America and Europe.

Want to learn more? Visit us at packaging.toppan.com

Summary Description:

Alloyd, a division of Toppan, is an industry leader in designing and producing innovative thermoformed packaging solutions for retail and food markets. Our focus on sustainability, quality, and engineering excellence drives our commitment to delivering packaging that protects products and enhances the customer experience.
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.
What you'll be doing:

• 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.

This position is located in DeKalb, IL and 100% onsite
We'd love to hear from you if:

• Bachelor's degree in Industrial Design, Mechanical Engineering, Packaging Engineering, or related field.
• 5+ 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.

Compensation:

The annual base salary range for this role is from $115,000 to $125,000

At TOPPAN Packaging Americas, We offer a comprehensive Total Rewards package designed to support our employees' overall wellbeing. This includes competitive pay, robust benefits, and programs that help you thrive both personally and professionally. Specific benefits and wellbeing programs may vary based on your work location, employment classification, or collective bargaining agreement.

Benefits

• Medical, dental, and vision coverage for you and your dependents, including FSA and HSA options
• 401(k) retirement plan with company match
• Wellbeing tools and resources to support holistic health, including an Employee Assistance Program with a variety of services
• Paid time off and holidays to recreate, rejuvenate and care for the health of yourself and family
• Variety of company paid and voluntary employee-paid insurance plans including life, personal accident, and disability insurance
• Tuition reimbursement

We are an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, creed, national origin, ancestry, ethnicity, sex (including pregnancy, childbirth, breastfeeding, and related medical conditions), gender identity or expression, sexual orientation, age, disability, genetic information, marital status, veteran or military status, citizenship status, or any other characteristic protected by applicable federal, state, or local laws.

We are committed to providing a workplace where everyone feels respected, valued, and able to contribute to their fullest potential. We also provide reasonable accommodations to individuals with disabilities throughout the application and employment processes. If you require assistance or accommodation due to a disability, please contact us.