Associate Engineer I - Thermoforming presso Sonoco

We are seeking a hands-on, detail-oriented R&D Associate to operate equipment and manage R&D trials focused on developing and testing new materials and new processes for packaging applications. The ideal candidate is a self-starter with deep expertise in compounding, sheet extrusion, lamination, and thermoforming, and a proven ability to troubleshoot and solve equipment problems independently. The position will be located at DeKalb, IL with up to 20% travel to our manufacturing plants to support scale-up trials.

What you'll be doing: 

• R&D Trial Support: Collaborate closely with R&D engineers to plan, execute, and document experimental trials. Provide process characterization and validation for new and revised materials and processes.

• Equipment Operation & Maintenance: Set up, operate, and maintain pilot-scale equipment including compounding and sheet extrusion lines. Process various resin materials such as PET, PP, HIPS, and bio resins, e.g., PLA.

• Process Documentation & Quality Verification: Accurately document process settings and experimental observations. Verify part quality using precision instruments including micrometers, Vernier calipers, and Magna Mike.

• Troubleshooting & Feedback: Identify nonconformances during trials and provide timely feedback to the R&D team.

• Manufacturing Transfer: Collaborate with Manufacturing to transfer pilot scale development to large manufacturing scale in our production plants.

• Customer Support: Take part with the technical team to run development trials at customer facilities.

• SOP Development: Assist in writing and updating standard operating procedures and other technical documentation as needed.

• Safety: Ensure compliance with company safety policies and procedures to protect all employees. Foster a positive, safe work environment through open communication and an atmosphere of teamwork

This position is in our DeKalb, IL Facility

We’d love to hear from you if:  

• 5-7 years of hands-on experience in sheet extrusion, lamination, and compounding processes. Experience with thermoforming is a plus.

• Familiarity with polymer processing and pilot-scale equipment.

• Strong mechanical aptitude and troubleshooting skills.

• Excellent documentation and communication abilities.

• Experience with precision measurement tools and quality verification techniques.

• Ability to work independently and in cross-functional teams.

• Bilingual in English & Spanish a plus

Additional Job Description:

• Position requires operating vacuum and pressure forming machines, extrusion machines, dryers and crystallizers, and thermoformers.

• Working with surface heights above 40”

• Lifting, pulling, or pushing up to 65 pounds?

• Standing 8-plus hours per day

• Exposure to hazards can include energy isolation, electricity, hot surface/contact, pinch points, moving machine parts, and fork truck traffic