Thermoform Design Engineer

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Hi Team,

We have an urgent requirement for a Thermoform Design Engineer with Tesla.

Job Title: Thermoform Design Engineer

Employment Type: Only W2

Locations: Austin, TX / Sparks, NV / Fremont, CA

Client: Tesla

Role Overview

Tesla is seeking a Thin-Gauge Thermoform Design Engineer to lead the design and development of thin-gauge thermoformed plastic components such as lightweight trays, packaging inserts, and enclosures.

This role involves complete ownership of thermoformed part and tooling design from concept through production, ensuring manufacturability, quality, and high-volume production readiness.

Key Responsibilities

Design thin-gauge thermoformed plastic components and tooling
Create detailed 3D CAD models, assemblies, and engineering drawings
Perform feasibility studies, tolerance analysis, and DFM optimization
Collaborate with manufacturing, quality, and supply chain teams
Support tooling fabrication, validation, and production launch
Work with toolmakers and machine shops on mold development
Optimize designs for trimming, wall thickness, and production efficiency

Required Skills

Bachelor s degree in Mechanical Engineering or related field
3+ years of experience in thermoformed plastic product/tooling design
Strong experience in thin-gauge thermoforming processes
Expertise in SolidWorks, CATIA, or similar 3D CAD tools
Strong knowledge of vacuum forming and pressure forming
Experience with thermoplastics such as ABS, HIPS, PETG, and PVC
Hands-on experience with thermoforming molds/tooling
Strong DFM, tolerance analysis, and feasibility study experience
Excellent communication and cross-functional collaboration skills

Preferred Qualifications

Automotive or high-volume manufacturing experience
Packaging engineering background
Knowledge of lean manufacturing and injection molding
Experience with CAE/FEA simulations
Familiarity with plastic industry standards and testing protocols

Thanks & Regards,

Sourabh Shukla

Technical Recruiter

Info Way Solutions LLC

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