Note: The job is a remote job and is open to candidates in USA. I3 INFOTEK INC is seeking an experienced Thin-Gauge Thermoform Design Engineer to design and develop thermoformed plastic components for automotive products and manufacturing operations. The role covers the full product development lifecycle, including CAD modeling, tooling design, material selection, manufacturability analysis, prototype validation, troubleshooting, and production launch while collaborating with cross-functional teams.
Responsibilities
- Design thin-gauge thermoformed plastic components including trays, packaging inserts, protective covers, and lightweight enclosures
- Develop detailed 3D CAD models, assemblies, engineering drawings, and manufacturing documentation using SolidWorks, CATIA, or equivalent CAD software
- Design thermoforming tooling and molds while collaborating with internal manufacturing teams and external toolmakers
- Perform feasibility studies, tolerance stack-up analysis, wall thickness optimization, and DFM reviews
- Select appropriate thermoplastic materials such as ABS, HIPS, PETG, PVC, and similar materials based on application requirements
- Support prototype development, tooling validation, first article inspections, and production launch activities
- Troubleshoot manufacturing issues related to thermoforming, trimming, tooling, and production quality
- Partner with manufacturing, quality, supply chain, and product engineering teams to optimize product performance and production efficiency
- Ensure designs comply with quality standards, cost targets, and production timelines
- Participate in design reviews and continuous improvement initiatives
Skills
- Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Design, or a related discipline
- Minimum 3+ years of experience designing thin-gauge thermoformed plastic products and tooling
- Strong experience with vacuum forming, pressure forming, and thin-gauge thermoforming processes
- Advanced proficiency in SolidWorks, CATIA, or equivalent 3D CAD software
- Experience designing thermoforming molds and collaborating with tooling vendors or machine shops
- Strong knowledge of thermoplastic materials including ABS, HIPS, PETG, PVC, and their forming characteristics
- Experience performing DFM analysis, tolerance analysis, material thickness optimization, and manufacturability reviews
- Strong understanding of high-volume manufacturing processes
- Excellent analytical, communication, and problem-solving skills
- Ability to work independently while collaborating effectively with cross-functional teams
- Experience in the automotive industry or other high-volume manufacturing environments
- Knowledge of lean manufacturing principles and automated production systems
- Experience with heavy-gauge thermoforming and injection molding processes
- Familiarity with CAE/FEA simulation tools for thermoformed part analysis
- Understanding of automotive or packaging industry standards and testing requirements
- Experience supporting tooling fabrication, validation, and production ramp-up
Benefits
- Remote work arrangement
- H1B, OPT, GC, USC visa eligibility
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