Design Engineer II

Suncast Corporation is the leading US-based designer, manufacturer, and distributor of high-quality resin products for the home and industrial markets. A privately held company headquartered in Western Chicago, Illinois, Suncast prides itself on 35 years of innovation and sustainability across a wide range of product categories with materials proudly sourced in the USA. Everything we do is supported by the strength and ingenuity of American workers and we are committed to helping families across the country make the most of their unique spaces. We utilize state-of-the-art machinery and innovative manufacturing techniques to consistently engineer products of the highest possible quality.

Position Summary:

The Design Engineer II is responsible for transforming product concepts into fully developed manufacturable products that align with Suncast’s quality, cost, and profitability objectives. This role requires evaluating and incorporating appropriate manufacturing processes and materials to ensure products meet target cost and margin requirements.

Design Engineers utilize CAD software extensively throughout the product development process and collaborate closely within a team-based engineering environment, often partnering with multiple engineers on a single project. The majority of design work focuses on injection-molded and blow-molded consumer products, with an emphasis on designing efficient, durable assemblies that typically minimize the use of mechanical fasteners. Products may incorporate metal tubing or other reinforcement materials as needed. In addition, Design Engineers support the development of products manufactured through profile extrusion processes.

This position combines technical design expertise, cross-functional collaboration, and manufacturing knowledge to deliver innovative, high-quality consumer products from concept through production.

The Anticipated Pay Range for This Position: $85K-$100K annually.

Suncast offers a comprehensive benefits package including:

Medical, Dental, Prescription Drugs, Vision insurance, Telehealth benefits

Group Term Life insurance

401K with employer match

Paid vacation time off

Paid holidays

Short- and long-term disability coverage

Health Savings Accounts (HSAs) & Flexible Spending Accounts (FSAs) for health

Paid Parental Leave (maternity & paternity)

Tuition Reimbursement

All qualified applicants will be given equal consideration regardless of race, age, sex, disability, sexual orientation, gender identity, marital status, color, religion, protected veteran status or national origin.

Responsibilities:

Develop an overall assembled product design using solid modeling techniques and the drawings and models from the senior product designer. Meet marketing, product, and cost criteria. Use a PC-based CAD system to complete development.

Work from the approved assembly design to develop components within the assembly.

Perform finite element analysis at various stages of product development to determine if the design will meet performance criteria.

Review tooling designs and production methods with the tool engineering group to develop tools for thermoplastic injection molding and profile extrusion. Suggest design modifications to improve productivity.

Review product designs with industrial engineering and automation engineering to ensure that the proper assembly processes and equipment are developed for the product.

Work with quality assurance department to develop appropriate tests for mechanical testing based on design intent.

Work closely with production and other engineering groups to eliminate problems, improve productivity, and decrease costs during the first production runs.

Ensure that the product designs meet the packaging intent during packaging development.

Ensure the product bill of materials and the cost build-up are accurate before the first pilot or production run.

Assist with model and prototype building. These models may be made from materials such as foam core, wood, and plastic. Processes such as RTV molds may be used.

Estimate initial component and product cost.

Evaluate product design and determine materials to be used. Consider factors such as function, production, and cost criteria.

Stay informed of new technology, methods, and materials within the field.

Support and comply with all Suncast safety policies, quality standards, and housekeeping practices.

Perform additional duties as required.

Qualifications:

Associate’s degree in CAD, Engineering Technology, or a related field with 1-3 years of product design experience preferred; Bachelor’s degree in Mechanical Engineering is a plus.

Experience or coursework in plastic part design preferred.

Strong analytical, problem-solving, and communication skills, with the ability to interpret technical documents and collaborate effectively across departments and with suppliers.

Proficiency in 3D CAD and solid modeling software; SolidWorks experience preferred.

Strong computer skills, including Microsoft Excel and standard business applications.

Ability to work in office, manufacturing, and workshop environments.

Occasional walking in production areas and regular standing during model shop activities and product testing.

Ability to lift up to 50 pounds as needed.

Willingness to work additional hours, including weekends, based on project and production demands.

Ability to wear required personal protective equipment (PPE) in manufacturing and workshop areas.

Occasional travel to suppliers and external vendors may be required.