Senior Hardware Product Packaging Engineer

San Mateo · USD 153,000-243,000 / year · Full-time · Hybrid · Posted Oct 9, 2026

At a glance

The Senior Hardware Product Packaging Engineer will own the end-to-end design and execution of packaging for Skydio's drone ecosystem, including commercial cartons and ruggedized field cases.
This cross-functional role bridges design, manufacturing, and supply chain to ensure products are protected for diverse environments ranging from patrol car trunks to battlefield scenarios.
The position involves managing the full packaging lifecycle from concept through mass production, including vendor technical management and transit testing.

Own customer-facing and enterprise-ready packaging from concept to mass production for aircraft, docks, controllers, and accessories.
Design packaging parts and assemblies in 3D CAD, including cushion geometry, cavity fits, and case interiors.
Partner with industrial design, product management, and marketing to craft the unboxing and use experience.
Engage with mechanical, electrical, and material flow engineering to ensure product safety and transport efficiency.
Manage technical activity at vendors including RFQs, tooling kickoffs, first article inspection, and quality criteria.
Design for various packaging processes such as corrugated, molded fiber, thermoforming, and injection molding.
Define and execute transit and field testing against standards like ISTA, ASTM D4169, ATA 300, and MIL-STD-810.
Own packaging compliance and labeling, including lithium battery shipping marks and regulatory documentation.
Support internal manufacturing teams with pack-out processes, line-side layout, and packaging BOMs.
Debug field damage and shipping returns to identify and resolve root causes.

Bachelor’s degree in mechanical engineering, packaging engineering, or equivalent.
Mastery of 3D CAD for developing complex assemblies.
Fluency in 2D structural design and artwork workflows, including die lines and dieline-to-print handoff.
Demonstrated ability to design for packaging manufacturing processes including corrugated, folding carton, foam conversion, and thermoforming.
Hands-on prototyping instinct for rapid sample creation.
Ability to produce thorough part and assembly drawings, specifications, and tolerance stacks.
Working knowledge of transit and field test standards.
Experience managing vendor relationships directly, including quoting, tooling timelines, and technical negotiation.
Strategic mindset across the full design, source, build, validate, and ship process.
Prior packaging or product development experience with a proven track record of execution.

Experience with CATIA.
Experience with molded fiber, roto-molding, injection molding, and soft goods.
Experience with ruggedized or mission-critical cases for defense, public safety, or industrial customers.
High-volume consumer electronics packaging experience, including retail channel and e-commerce requirements.

Role involves travel to supplier sites, including domestic and international locations.