Staff Engineer, Tool Design (R4967)

The Senior Tool Design Engineer brings 7+ years of experience developing production tooling for complex aerospace systems. This role owns tooling throughout its lifecycle (concept, design, analysis, release, fabrication, and prove-out) ensuring safe, repeatable, first-time-right assembly. You will work cross-functionally with Manufacturing, Quality, and Safety to deliver robust tooling that supports pilot builds through rate production.

Responsibilities

Translate GD&T, key characteristics, and CTQs into tooling requirements (datums, locators, clamps, tolerances, ergonomics, ESD/FOD controls); Design assembly jigs, drill/bond fixtures, composites molds & trim fixtures, go/no-go gauges, lifting/handling carts, and protective tooling using CATIA/NX/SolidWorks; Conduct FEA and hand calculations to confirm stiffness, clamp loads, safety factors, and ergonomics; Generate complete Tool Design Packages including 3D models, 2D drawings with GD&T, BOM, torque/fastener specs, materials/finishes, lifting points, and safety labeling; Lead design reviews with ME, Quality, Safety, and Launch teams; perform human-factors evaluations; Manage tool fabrication, oversee NCR/ECR resolution, and support shop-floor prove-out; Develop Tool Setup & Care Instructions, PM plans, and inspection checklists; Support First Article activities including CMM/laser-tracker alignment, gage strategy, and dimensional validation

Requirements

7+ years of experience in tooling design, mechanical design, or manufacturing engineering; Bachelor’s degree in Mechanical, Aerospace, Industrial, Mechatronics, or related engineering field; Experience in prototype manufacturing in a startup or rapid-growth environment; Strong understanding of manufacturing processes, including machining, composites, avionics and/or assembly; Demonstrated ability to work in a fast-paced, high-pressure environment and adapt to changing priorities; CATIA / NX / SolidWorks; 3DEXPERIENCE / Teamcenter; FEA tools; GD&T; metrology fundamentals; supplier manufacturing processes

Nice to have

Knowledge of quality standards, such as AS9100 or ISO 9001; Familiarity with advanced manufacturing technologies, such as additive manufacturing or automation systems; Strong project management skills, including experience managing multiple priorities and deadlines

Benefits

Bonus; Benefits; Equity