Mechanical Engineer 4

United Launch Alliance•Decatur, AL

2d•Onsite

About The Position

United Launch Alliance is seeking a Mechanical Engineer to lead the design, analysis, and development of tooling used in aerospace manufacturing and integration. The role covers advanced tooling, fixtures, lift devices, and assembly aids, from initial design through fabrication, installation, validation, and production support. The engineer develops complete design packages and verifies tooling performance, safety, ergonomics, quality, and manufacturability in coordination with Manufacturing Engineering, Production, Quality, and M&P teams. The position also manages tooling projects, investigates production and integration issues, supports continuous improvement, and ensures compliance with applicable aerospace, lifting, handling, and safety standards. It includes mentoring junior engineers and providing technical guidance across the tooling organization. The role is based at ULA in Decatur, with 10% travel and no relocation offered. The posting notes ITAR requirements: applicants must be U.S. Persons as defined by the cited regulations.

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.
Proficiency in CAD; the posting identifies Creo, NX, and CATIA as commonly used aerospace platforms.
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 ME, M&P, Quality, Production, and Launch Operations teams.
Ability to mentor junior tool engineers or technicians.
Must be a U.S. Person under the applicable ITAR definition.

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 expertise 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 factory-floor tooling validation experience, including Gage R&R, buyoff, and metrology alignment.
Knowledge of AS9100, NASA, DoD, or MIL-STD manufacturing requirements.
Experience with DFM/DFA, lean manufacturing, 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.
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.
Ability to mentor junior engineers and influence engineering strategy.

Responsibilities

Lead design, analysis, and development of tooling, fixtures, lift devices, and assembly aids for aerospace manufacturing and integration.
Create complete tool design packages, including 3D models, drawings, GD&T, tolerance analyses, and specifications.
Provide technical oversight during fabrication, tooling buyoff, installation, validation, and production support.
Collaborate with Manufacturing Engineering, Production, Quality, and M&P teams to establish tooling needs and ensure safety, ergonomics, quality, and manufacturability.
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-related production or integration issues.
Manage projects, including schedules, cost estimates, supplier coordination, and risk mitigation.
Support continuous improvement, including automation, lean tooling strategies, and workflow optimization.
Ensure tooling compliance with ASME, OSHA, and aerospace industry standards for lifting, handling, and safety.
Mentor junior engineers and provide technical guidance across the tooling organization.