Senior Tooling Design Engineer, Airframe Manufacturing

Astro Mechanica • San Francisco, CA

4d • $150,000 - $190,000 • Onsite

About The Position

Astro Mechanica is a vertically integrated aerospace company building a faster, more connected future. Our mission is to democratize high-speed flight by making supersonic travel flexible, accessible, and sustainable. We believe that rapid, on-demand, point-to-point global mobility will become the new standard for moving people and goods across the planet. To achieve this, we are integrating our advanced airframe and engine technologies—which include Duality™, our proprietary dual-use propulsion system—with a new flight operations model to make supersonic transport as efficient and economical as commercial air travel is today. In the near term, we are developing adaptable, high-speed systems to close aircraft performance gaps for the United States government.

We’re a team of passionate engineers dedicated to advancing aerospace. We’re generalists with specialist depth, united by a flat structure and a shared obsession with building things that work well. We move fast, stay pragmatic, and let engineering excellence speak louder than hierarchy.

You're an engineer with a strong mechanical design background and experience developing tooling systems for large and complex assemblies. You are looking for an opportunity to deploy your skills to tackle difficult manufacturing challenges and design assembly fixtures from the ground up. You thrive in a hands-on, interdisciplinary environment where you are responsible for the entire scope of the tooling project; from initial design through successful implementation. You’re able to collaborate seamlessly with manufacturing and design teams to develop elegant tooling systems that will help lay the foundation for our next-generation aircraft factory.

Requirements

• 7+ years of experience designing aircraft or aerospace tooling and assembly fixturing, including full lifecycle ownership through design, procurement, fabrication, proof-out, and production support
• Degree in Mechanical, Aerospace, or Manufacturing Engineering or equivalent
• Demonstrated experience designing both large monolithic assembly fixtures for major airframe assembly and small detail tooling such as drill jigs, trim fixtures, bond fixtures, and shop aids
• Strong hands-on experience with composite assemblies, including cure tooling, bond fixtures, and the tooling implications of layup, cure, trim, drill, and bonded joint processes
• Practical experience with weldments and machined metallic structure, including weld distortion control, fixture design for welded assemblies, and composite-to-metal interfaces
• Expert proficiency in an industry standard 3D CAD system, preferably NX, including large assembly management and surfacing
• Applied experience with GD&T and detailed tolerance stack-up analysis across a multi-stage build sequence
• Demonstrated experience defining locating and datum schemes for large, complex primary structure
• Experience with metrology-driven assembly using laser tracker, CMM, or photogrammetry for tool setup, certification, and periodic recertification
• Experience selecting tool materials and fabrication methods based on CTE, stiffness, durability, cost, and lead time
• Experience owning tooling budget, schedule, vendor selection, and delivery for a program's full tooling package
• Experience leading DFM initiatives and working closely with design teams to influence product architecture for manufacturability and assembly
• Ability to work directly from engineering drawings, CAD models, and evolving build definitions
• Proven ability to lead and mentor engineers and technicians while staying deeply engaged in the technical details
• Demonstrated experience and strong desire to work closely with the production team on the shop floor

Nice To Haves

• Experience standing up a tooling function or tool room from scratch, including equipment, vendor base, standards, and documentation
• Experience with determinant assembly and full-size airframe assembly
• FEA experience validating tool stiffness, deflection, and load paths
• CAM programming and hands-on machining experience
• Welding and weld fixture design experience, including familiarity with welded structure inspection
• Experience with laser projection systems to aid composite layup and assembly
• Experience with ply pattern generation and composite design tools (Fibersim, Composite Workbench, or similar)
• Experience with aircraft or spacecraft integration
• Experience with NDI and quality inspection methods for composite and bonded structure
• Experience transitioning tooling from prototype builds into higher rate production
• Familiarity with AS9100, NADCAP, or FAA/DoD requirements applicable to aerospace tooling
• Has owned the upkeep side of a tooling library: recertification intervals, tracking, and planned maintenance
• Experience manufacturing large structures

Responsibilities

• Own the tooling strategy for Astro Mechanica's airframe, defining the fixturing and jigging architecture that carries us from detail part through to a joined airframe
• Design and deliver large assembly fixtures for major airframe assembly, along with the drill jigs, trim and bond fixtures, layup tools, and shop aids that feed them
• Establish the locating and datum strategy across the build sequence, and own the tolerance stack-up and GD&T analysis that proves the airframe closes
• Help stand up our tooling function from scratch, including design standards, drawing practice, tool numbering, vendor base, and proof-out process
• Serve as the technical authority on tooling for composite and metallic airframe structure, guiding design teams on manufacturability, tool access, and assembly approach
• Carry tooling from purchase order through build, install, and certification, whether it is made in-house or bought outside, holding the budget, schedule, and vendor choice
• Run tool proof-out and first article builds alongside the technicians who will use them, and close out whatever the trial exposes
• Define the metrology approach for tool certification and recertification, and interpret laser tracker and CMM results
• Mentor early-career tool designers and technicians, and build out the team's design review practice
• Own the investigation when a tool is implicated in a defect, and drive the corrective action to closure
• Hold our tooling to the ergonomic, safety, quality, and documentation bar that aerospace work demands
• Plan the transition of tooling from prototype builds toward higher rate production, designing for reuse and scalability
• Seek out new tooling technologies and methods that improve build speed, accuracy, and repeatability

Benefits

• Comprehensive medical, dental, and vision insurance, including Flexible Spending Accounts (FSA)
• 401(k) program and transparent stock option plan
• Self-managed and flexible time-off policy, including PTO, paid holidays, and sick time
• Flexible work environment

What This Job Offers

• Job Type: Full-time
• Career Level: Senior