Mechanical Engineer 4

ULA•Decatur, IL

13h•Onsite

About The Position

United Launch Alliance is hiring a Mechanical Engineer to lead the design, analysis, and development of advanced tooling, fixtures, lifting devices, and assembly aids for aerospace manufacturing and integration. The role develops complete tooling design packages, including 3D models, drawings, GD&T, tolerance analyses, and specifications, and provides technical oversight through fabrication, buyoff, installation, validation, and production support. The engineer works with Manufacturing Engineering, Production, Quality, and Materials and Processes teams to define tooling requirements and ensure solutions address safety, ergonomics, quality, and manufacturability. The position includes engineering analysis, issue investigation and corrective action, project management, continuous improvement, standards compliance, and mentoring junior engineers. The role is based at ULA in Decatur, with 10% travel and no relocation offered. Applicants must be U.S. persons as defined by ITAR because the position involves access to ITAR-controlled information.

Requirements

Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Aerospace Engineering, or a related technical field.
At least 6 years of engineering experience, with significant emphasis on tooling and fixtures.
Strong CAD proficiency; aerospace platforms include Creo, NX, or CATIA.
Ability to design complex aerospace tooling, including lifting and handling fixtures, assembly jigs, precision alignment tooling, and composite layup or metallic fabrication tooling.
Ability to perform tolerance stackups and apply GD&T per ASME Y14.5.
Experience with aerospace manufacturing processes such as machining, composites, welding, metrology, or assembly integration.
Knowledge of MIL-STD and aerospace safety and ergonomics requirements, including lift safety, FMEA, and risk reduction.
Ability to lead tooling projects independently with minimal oversight.
Experience writing technical documentation, tooling specifications, procurement packages, and change control.
Ability to collaborate across Manufacturing Engineering, M&P, Quality, Production, and Launch Operations teams.
Ability to mentor junior tool engineers or technicians.
Must be a U.S. person as defined by ITAR.

Nice To Haves

Master’s degree in Mechanical, Manufacturing, or Aerospace Engineering.
6–10+ years of tooling engineering experience, particularly supporting flight hardware or large aerospace structures.
Advanced experience with Creo, CATIA, or NX, including surfacing, large assembly management, and kinematic or mechanism modeling.
Experience with automated tooling systems, robotics, or PLC-controlled fixtures.
Background with composites tooling, autoclave molds, or metallic forming dies.
Hands-on experience validating tooling on the factory floor, including Gage R&R, buyoff, and metrology alignment.
Knowledge of AS9100, NASA, DoD, or MIL-STD manufacturing requirements.
Experience in DFM/DFA, lean manufacturing practices, and ergonomics optimization.
Ability to lead cross-functional technical teams or direct suppliers through fabrication and qualification.
Experience with stress analysis, FEA, or structural validation of lifting and handling devices.
Strong understanding of crane and lifting safety, load certification, and OSHA regulations.
Experience supporting launch vehicle tooling, spacecraft structures, large tanks, or precision alignment operations in VAB, ITL, or integration environments.
Demonstrated ability to mentor junior engineers and influence engineering strategy.

Responsibilities

Lead the design, analysis, and development of tooling, fixtures, lifting devices, and assembly aids for aerospace manufacturing and integration.
Create complete tool design packages, including 3D models, drawings, GD&T, tolerance analyses, and specification documents.
Provide technical oversight during fabrication, tooling buyoff, installation, validation, and production support.
Partner with Manufacturing Engineering, Production, Quality, and M&P teams to define tooling needs and meet safety, ergonomics, quality, and manufacturability requirements.
Conduct engineering analyses to validate tooling performance, including stress checks, load paths, fit-up, and tolerance stacks.
Investigate root causes and drive corrective actions for tooling issues affecting production or integration.
Manage project schedules, cost estimates, supplier coordination, and risk mitigation.
Support continuous improvement initiatives, including automation, lean tooling strategies, and workflow optimization.
Ensure tooling complies with ASME, OSHA, and aerospace standards for lifting, handling, and safety.
Mentor junior engineers and provide technical guidance across the tooling organization.