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Position: Thin-Gauge Thermoform Design Engineer

Location:            REMOTE

Mode: Contract 6+ Months

Job Summary: 

This role focuses on designing thin-gauge thermoformed plastic components (e.g. lightweight trays, enclosures, packaging inserts) for Automotive OEM’s products and operations.

The engineer leads end-to-end design of thermoformed parts and tooling from concept through production, ensuring design for manufacturability in thin plastic sheet forming (typically <1.5 mm thickness).

Responsibilities include creating detailed 3D CAD models and drawings, conducting feasibility and tolerance analyses to optimize designs, and collaborating cross-functionally with manufacturing, quality, and supply chain teams to meet high-volume production and quality standards.

The engineer also supports tooling fabrication and validation with internal teams or external toolmakers to ensure that thermoforming molds and processes achieve the required performance and precision. (Notably there is flexibility for these specialized roles, even considering remote work arrangements.) This is a hands-on design position requiring technical expertise in thin-gauge thermoforming processes, creativity in problem-solving, and strong coordination skills.

Required Skills/Qualifications:

A solid foundation in mechanical design and specific experience with thin-gauge thermoforming is essential.
Key requirements typically include:

•            Education & Experience: A B.S. in Mechanical Engineering or a related field (e.g. Manufacturing or Industrial Design) and 3+ years of experience designing thermoformed plastic products and tooling – particularly in thin-gauge applications (e.g. packaging or lightweight enclosures).

•            CAD Proficiency: Advanced skill in 3D CAD software (such as SolidWorks, CATIA, or equivalent) for complex part modeling, assembly design, and detailed drawing creation.

•            Thermoforming Process Knowledge: Strong understanding of thin-gauge thermoforming processes, including vacuum forming and pressure forming techniques. Familiarity with thermoplastic materials commonly used in thin-gauge thermoforming (e.g. ABS, HIPS, PETG, PVC) and how they behave under heat and vacuum is critical.

•            Tooling & DFM Skills: Experience in designing thermoforming molds/tooling and collaborating with toolmakers or machine shops for fabrication and validation of those tools. Ability to optimize part designs for manufacturability, trimming, and high-volume production (DFM) is required.

•            Analytical & Quality Focus: Competence in tolerance analysis, material thickness optimization, and part feasibility studies for thin-gauge parts. Strong attention to detail with quality control considerations for plastic part integrity and consistency.

•            Collaboration & Communication: Ability to work with cross-functional teams (design engineering, manufacturing, quality, supply chain) to refine requirements and ensure successful integration of thermoformed components into the overall system. Excellent communication skills are essential for bridging design with production.

Preferred Skills/Pluses:

Candidates with the following are often preferred in thin-gauge thermoforming roles, per industry and Automotive OEM’s practices:

•            Industry Exposure: Prior experience in an automotive or high-volume manufacturing environment, especially involving packaging engineering or plastic component design, is a strong plus (demonstrates ability to meet rigorous performance and quality standards at scale).

•            Advanced Manufacturing Knowledge: Familiarity with lean/automated manufacturing processes and related plastic forming methods (e.g. heavy-gauge thermoforming or injection molding) is beneficial to broaden problem-solving approaches in design.

•            Simulation & Analysis: Experience with CAE/FEA tools for simulating thermoformed part behavior or design optimization can be advantageous, enabling better prediction of material performance (e.g. shrinkage, wall thinning).

•            Standards & Compliance: Knowledge of industry standards and testing protocols relevant to thin-gauge plastics (such as packaging standards or automotive component requirements) is helpful, especially if the role involves ensuring designs meet safety, durability, or regulatory criteria.