Note: The job is a remote job and is open to candidates in USA. KTek Resourcing is seeking a Thin-Gauge Thermoform Design Engineer to design lightweight thermoformed plastic components for automotive OEM products and operations. The role leads end-to-end design of thermoformed parts and tooling from concept through production, including CAD modeling, feasibility and tolerance analysis, design for manufacturability, and collaboration on tooling fabrication and validation.
Responsibilities
- Creating detailed 3D CAD models and drawings
- Conducting feasibility and tolerance analyses to optimize designs
- Collaborating cross-functionally with manufacturing, quality, and supply chain teams to meet high-volume production and quality standards
- Supports tooling fabrication and validation with internal teams or external toolmakers to ensure that thermoforming molds and processes achieve the required performance and precision
Skills
- • 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
- • 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
Benefits
- Remote work arrangements
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