Project Engineer

About the role

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.

Responsibilities

• 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.

Requirements

• 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.
• Familiarity with 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.

Qualifications

• Experience with 3D scanning and 3D printing technologies.
• Understanding of industry standards and regulations relevant to food and retail packaging.
• Knowledge of regulatory compliance for packaging materials and processes.

Skills

• Thermoformed packaging design and development.
• Material selection and evaluation.
• Tooling design and manufacturing processes.
• Design feasibility studies and risk assessment.
• Collaboration with cross-functional teams.
• Customer engagement and presentation skills.
• Problem-solving and critical thinking.

Benefits

• Comprehensive Total Rewards package including competitive pay, benefits, and wellness programs.
• Medical, dental, and vision coverage.
• 401(k) retirement plan with company match.
• Paid time off and holidays.
• Tuition reimbursement.

Pay

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

Schedule

This position is located in DeKalb, IL and is 100% onsite.

Equal Opportunity Employer

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.