Senior Staff Packaging EngineerLocation: Leesburg, VA (5-15% Travel)
Compensation: $128,000 - $136,000 Base Salary + Performance Bonus Potential
Position Summary The Senior Staff Packaging Engineer serves as a technical leader responsible for the design, development, validation, and continuous improvement of sterile and non-sterile medical device packaging systems. This individual will lead packaging projects from concept through commercialization while partnering with cross-functional engineering teams, suppliers, and manufacturing operations to deliver reliable, compliant, and cost-effective packaging solutions.
This role offers significant ownership over packaging strategy, design standards, testing protocols, and continuous improvement initiatives supporting new product development.
Responsibilities - Lead the design, development, and implementation of sterile and non-sterile medical device packaging systems from concept through production release.
- Develop packaging design standards, engineering procedures, and best practices that optimize product protection, manufacturability, cost, and regulatory compliance.
- Create detailed packaging designs and engineering documentation utilizing CAD software (SolidWorks or Creo preferred).
- Develop specifications for primary, secondary, and tertiary packaging components.
- Design, execute, and analyze packaging validation and performance testing to ensure compliance with applicable regulatory and quality standards.
- Partner with Product Development, Manufacturing, Quality, Regulatory, and Supply Chain teams throughout new product development programs.
- Design transportation cases, trays, and packaging systems supporting sterilization, shipment, storage, and clinical use.
- Lead packaging-related risk assessments including DFMEA, PFMEA, and other design control documentation.
- Collaborate with suppliers and contract manufacturers to optimize packaging designs, improve manufacturability, and reduce overall costs.
- Identify and implement continuous improvement and value engineering opportunities while maintaining product quality and performance.
- Stay current on emerging packaging materials, technologies, and industry best practices.
Required Qualifications - Bachelor's degree in Packaging Engineering, Mechanical Engineering, Materials Science, Quality Engineering, Microbiology, or a related technical discipline.
- Minimum 6 years of experience in packaging engineering or packaging design and development.
- Minimum 2 years of CAD design experience utilizing SolidWorks, Creo, or similar software.
- Strong understanding of medical device packaging requirements, Quality System Regulations (QSR), and packaging validation methodologies.
- Experience managing multiple engineering projects within a regulated manufacturing environment.
- Strong technical communication, project management, and cross-functional leadership skills.
Preferred Experience - Medical device packaging design.
- Sterile packaging systems.
- Packaging validation and testing.
- Transportation and distribution packaging.
- Risk management (DFMEA/PFMEA).
- Supplier collaboration and design for manufacturability.
- Cost reduction and value engineering initiatives.
- New product development within regulated manufacturing environments.
Benefits - Competitive base salary
- Performance-based bonus opportunity
- Medical, Dental & Vision Insurance
- 401(k) with Company Match
- Paid Time Off & Holidays
- Paid Parental Leave
- Professional Development & Training
- Career Advancement Opportunities
Additional Information - Full-time, onsite position based in Leesburg, VA.
- Approximately 5-15% travel required.
- Opportunity to serve as a technical leader within a collaborative R&D organization while developing innovative packaging solutions supporting advanced medical technologies.
Compensation: $128,000 - $136,000 Base Salary + Performance Bonus Potential
• Pay for this role is competitive and based on experience, qualifications, and performance. The typical compensation range is $128,000-$136,000 annually, with eligibility for performance-based bonuses and a comprehensive benefits package. Final compensation is determined based on experience level, technical expertise, and overall market alignment.
