Thermoform Design Engineer

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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