Staff Engineer – Tool Design

About the role

The Senior Tool Design Engineer will own the full lifecycle of production tooling for complex aerospace systems, from concept through prove‑out. This position works closely with Manufacturing, Quality, and Safety to ensure safe, repeatable, first‑time‑right assembly for pilot builds and rate production.

Key responsibilities

• Translate GD&T, key characteristics, and CTQs into tooling requirements such as datums, locators, clamps, tolerances, ergonomics, and ESD/FOD controls.
• Design assembly jigs, drill/bond fixtures, composite molds, trim fixtures, go/no‑go gauges, lifting/handling carts, and protective tooling using CATIA, NX, or SolidWorks.
• Conduct FEA and hand calculations to verify 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 Manufacturing Engineering, 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, preventive‑maintenance plans, and inspection checklists.
• Support First Article activities, including CMM/laser‑tracker alignment, gauge strategy, and dimensional validation.

Required profile

• 7+ years of experience in tooling design, mechanical design, or manufacturing engineering.
• Bachelor’s degree in Mechanical, Aerospace, Industrial, Mechatronics, or a related engineering field.
• Experience in prototype manufacturing within a startup or rapid‑growth environment.
• Strong understanding of manufacturing processes, including machining, composites, avionics, and assembly.
• Proven ability to thrive in a fast‑paced, high‑pressure environment and adapt to changing priorities.

Required skills

• CATIA, NX, SolidWorks
• 3DEXPERIENCE, Teamcenter
• FEA tools
• GD&T and metrology fundamentals
• Supplier manufacturing processes