Thin‑Gauge Thermoform Design Engineer W2 Remote Job

Role: Thin‑Gauge Thermoform Design Engineer

Location: Remote (Onsite flexibility may apply)

Start Date: Immediate availability

Job Type: Contract (C2C/W2)

Interview Mode: Phone/Video 

We are seeking a Thin‑Gauge Thermoform Design Engineer to design lightweight thermoformed plastic components such as trays, enclosures, and packaging inserts. This role covers end‑to‑end design of thermoformed parts and tooling, from concept through production, ensuring manufacturability and compliance with high‑volume standards.

Key Responsibilities:

• Create detailed 3D CAD models and drawings

• Conduct feasibility and tolerance analyses for thin‑gauge parts (<1.5 mm)

• Collaborate with manufacturing, quality, and supply chain teams

• Support tooling fabrication and validation with internal teams and toolmakers

• Ensure designs meet performance, precision, and quality requirements

Required Skills & Qualifications:

• Bachelor’s degree in Mechanical Engineering or related field

• 3+ years of experience in thin‑gauge thermoforming design

• Advanced proficiency in CAD (SolidWorks, CATIA, or equivalent)

• Strong knowledge of thermoforming processes (vacuum forming, pressure forming)

• Familiarity with thermoplastic materials (ABS, HIPS, PETG, PVC)

• Experience in tooling design, DFM, and high‑volume production

• Competence in tolerance analysis and feasibility studies

• Strong communication and cross‑functional collaboration skills

Preferred Skills:

• Automotive or high‑volume manufacturing experience

• Knowledge of lean/automated manufacturing processes

• Exposure to CAE/FEA simulation for thermoformed parts

• Familiarity with industry standards and testing protocols for plastics

All your information will be kept confidential according to EEO guidelines.