Senior Staff Packaging Engineer

Responsibilities

• Lead the design, development, and implementation of sterile and non-sterile medical device packaging systems from concept through production release.
• Develop packaging design standards, engineering procedures, and best practices that optimize product protection, manufacturability, cost, and regulatory compliance.
• Create detailed packaging designs and engineering documentation utilizing CAD software (SolidWorks or Creo preferred).
• Develop specifications for primary, secondary, and tertiary packaging components.
• Design, execute, and analyze packaging validation and performance testing to ensure compliance with applicable regulatory and quality standards.
• Partner with Product Development, Manufacturing, Quality, Regulatory, and Supply Chain teams throughout new product development programs.
• Design transportation cases, trays, and packaging systems supporting sterilization, shipment, storage, and clinical use.
• Lead packaging-related risk assessments including DFMEA, PFMEA, and other design control documentation.
• Collaborate with suppliers and contract manufacturers to optimize packaging designs, improve manufacturability, and reduce overall costs.
• Identify and implement continuous improvement and value engineering opportunities while maintaining product quality and performance.
• Stay current on emerging packaging materials, technologies, and industry best practices.

Requirements

• Bachelor's degree in Packaging Engineering, Mechanical Engineering, Materials Science, Quality Engineering, Microbiology, or a related technical discipline.
• Minimum 6 years of experience in packaging engineering or packaging design and development.
• Minimum 2 years of CAD design experience utilizing SolidWorks, Creo, or similar software.
• Strong understanding of medical device packaging requirements, Quality System Regulations (QSR), and packaging validation methodologies.
• Experience managing multiple engineering projects within a regulated manufacturing environment.
• Strong technical communication, project management, and cross-functional leadership skills.

Qualifications

• Preferred Experience:
• Medical device packaging design.
• Sterile packaging systems.
• Packaging validation and testing.
• Transportation and distribution packaging.
• Risk management (DFMEA/PFMEA).
• Supplier collaboration and design for manufacturability.
• Cost reduction and value engineering initiatives.
• New product development within regulated manufacturing environments.

Benefits

• Competitive base salary
• Performance-based bonus opportunity
• Medical, Dental & Vision Insurance
• 401(k) with Company Match
• Paid Time Off & Holidays
• Paid Parental Leave
• Professional Development & Training
• Career Advancement Opportunities

Additional Information

Full-time, onsite position based in Leesburg, VA. Approximately 5–15% travel required.

Opportunity to serve as a technical leader within a collaborative R&D organization while developing innovative packaging solutions supporting advanced medical technologies.

Compensation: $128,000 - $136,000 annually, with eligibility for performance-based bonuses and a comprehensive benefits package.