[Remote] Thin-Gauge Thermoform Design Engineer

Note: The job is a remote job and is open to candidates in USA. HCLTech is looking for a highly talented and self-motivated Thin-Gauge Thermoform Design Engineer to join its team in advancing the technological world through innovation and creativity. The role focuses on designing thin-gauge thermoformed plastic components for Automotive OEM’s products, leading the design process from concept through production while ensuring manufacturability and quality standards.ResponsibilitiesThis role focuses on designing thin-gauge thermoformed plastic components (e.g. lightweight trays, enclosures, packaging inserts) for Automotive OEM’s products and operationsThe engineer leads end-to-end design of thermoformed parts and tooling from concept through production, ensuring design for manufacturability in thin plastic sheet forming typically Responsibilities include creating detailed 3D CAD models and drawings, conducting feasibility and tolerance analyses to optimize designs, and collaborating cross-functionally with manufacturing, quality, and supply chain teams to meet high-volume production and quality standardsThe engineer also supports tooling fabrication and validation with internal teams or external toolmakers to ensure that thermoforming molds and processes achieve the required performance and precision. (Notably there is flexibility for these specialized roles, even considering remote work arrangements.) This is a hands-on design position requiring technical expertise in thin-gauge thermoforming processes, creativity in problem-solving, and strong coordination skillsSkillsA B.S. in Mechanical Engineering or a related field (e.g. Manufacturing or Industrial Design)3+ years of experience designing thermoformed plastic products and tooling – particularly in thin-gauge applications (e.g. packaging or lightweight enclosures)Advanced skill in 3D CAD software (such as SolidWorks, CATIA, or equivalent) for complex part modeling, assembly design, and detailed drawing creationStrong understanding of thin-gauge thermoforming processes, including vacuum forming and pressure forming techniquesFamiliarity with thermoplastic materials commonly used in thin-gauge thermoforming (e.g. ABS, HIPS, PETG, PVC) and how they behave under heat and vacuumExperience in designing thermoforming molds/tooling and collaborating with toolmakers or machine shops for fabrication and validation of those toolsAbility to optimize part designs for manufacturability, trimming, and high-volume production (DFM)Competence in tolerance analysis, material thickness optimization, and part feasibility studies for thin-gauge partsStrong attention to detail with quality control considerations for plastic part integrity and consistencyAbility 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 systemExcellent communication skills are essential for bridging design with productionPrior experience in an automotive or high-volume manufacturing environment, especially involving packaging engineering or plastic component designFamiliarity with lean/automated manufacturing processes and related plastic forming methods (e.g. heavy-gauge thermoforming or injection molding)Experience with CAE/FEA tools for simulating thermoformed part behavior or design optimizationKnowledge of industry standards and testing protocols relevant to thin-gauge plastics (such as packaging standards or automotive component requirements)BenefitsPerformance-based bonuses subject to company policiesMedical, dental, vision, pharmacy, life, accidental death & dismemberment, and disability insuranceEmployee assistance program401(k) retirement plan10 days of paid time off per year (some positions are eligible for need-based leave with no designated number of leave days per year)10 paid holidays per yearContinuous opportunities for you to find your spark and grow with usTransparent communication with senior-level employeesLearning and career development programs at every levelOpportunities to experiment in different roles or even pivot industriesCompany OverviewHCLTech is a global IT company offering digital, engineering, and cloud solutions partnering with businesses for transformation. It was founded in 1976, and is headquartered in Noida, Uttar Pradesh, IND, with a workforce of 10001+ employees. Its website is https://www.hcltech.com/.Company H1B SponsorshipHCLTech has a track record of offering H1B sponsorships, with 243 in 2026, 2972 in 2025, 3974 in 2024, 3649 in 2023, 3861 in 2022, 4093 in 2021, 4317 in 2020. Please note that this does not guarantee sponsorship for this specific role.