Thin gauge Thermoform Design Engineer

About the role

Design and develop thin-gauge thermoformed plastic components and tooling for high-volume manufacturing applications.

Responsibilities

• Create detailed 3D models, assemblies, and engineering drawings using CAD tools such as SolidWorks, CATIA, or equivalent.
• Apply expertise in vacuum forming, pressure forming, and thin-gauge thermoforming processes to optimize product designs.
• Design thermoforming molds and tooling while collaborating with toolmakers and machine shops for fabrication and validation.
• Optimize component designs for manufacturability (DFM), trimming, cost reduction, and production efficiency.
• Perform tolerance analysis, material thickness optimization, and feasibility studies to ensure part quality and performance.
• Select and evaluate thermoplastic materials such as ABS, HIPS, PETG, and PVC based on application requirements.
• Collaborate with Design Engineering, Manufacturing, Quality, and Supply Chain teams to ensure seamless product integration.
• Support quality assurance activities by ensuring compliance with dimensional, durability, and performance standards.
• Utilize CAE/FEA tools to analyze thermoformed part behavior, including shrinkage, wall thinning, and structural performance.
• Apply knowledge of lean manufacturing, automation, injection molding, and related plastic forming processes to improve designs.
• Ensure compliance with automotive, packaging, and industry standards while supporting continuous improvement and high-volume production initiatives.