Senior Tooling Engineer
About The Position
Thea Energy is seeking a Senior Tooling Engineer to lead the design, build, and factory-floor implementation of large, heavy custom tooling and specialized handling equipment for a first-of-a-kind fusion energy system. In this role, you will work closely with design and manufacturing teams to take full ownership of tooling from early conceptual CAD through fabrication, load testing, commissioning, and operational deployment. While primary focus is on heavy tooling design and hardware implementation, you will also support physical integration and assembly planning to ensure multi-ton, complex hardware can be built, handled, and maintained safely and repeatably. You are comfortable moving seamlessly between CAD modeling, supplier fabrication shops, engineering reviews, and hands-on rigging and hardware installation on the factory floor.
Requirements
- 8+ years of progressive experience in custom tooling design, mechanical engineering, heavy equipment design, or hardware integration.
- Proven track record of designing, building, and deploying large, heavy custom tooling, multi-ton fixtures, lift frames, or specialized assembly equipment.
- Direct familiarity and hands-on exposure to rigging principles, heavy lifting practices, spreader bar design, crane operations, and load testing standards.
- Expert knowledge of structural design, welded steel structures, stress analysis, GD&T, tolerance stack-up, and mechanical interfaces.
- Expertise in 3D CAD modeling (NX preferred) and finite element analysis in COMSOL or Ansys for custom machined/welded structures.
- Experience developing assembly and integration processes, DFM/DFA, and hands-on support for manufacturing and installation.
- Experience with precision alignment, metrology tools (e.g., laser trackers), and large electro-mechanical hardware assembly.
- Background in nuclear, aerospace, fusion, heavy equipment, shipbuilding, semiconductor, or other highly engineered hardware industries.
- Strong interpersonal communication and cross-functional leadership skills, with the ability to work hands-on with design, manufacturing, and rigging teams.
Responsibilities
- Lead the full design, analysis, procurement, fabrication, and commissioning of large, heavy custom tooling, fixtures, and jigs for manufacturing and test.
- Develop custom lifting rigs, spreader bars, turn-over fixtures, and heavy handling equipment while establishing safe rigging protocols for multi-ton hardware.
- Define structural, mechanical, interface, and safety requirements for custom tooling, ensuring compliance with applicable lifting and rigging safety standards.
- Manage vendor and fabrication shop relationships for the build, machining, proof-load testing, and delivery of heavy tooling assemblies.
- Drive Design-for-Manufacturability (DFM) and Design-for-Assembly (DFA) input into design engineering to optimize hardware interfaces for custom tooling and handling.
- Support development of physical assembly, installation, and integration sequences for complex nuclear and industrial hardware.
- Define precise tooling requirements for positioning, joining, inspection, testing, and precision metrology alignment strategies.
- Develop detailed work instructions, lift plans, and operational procedures for heavy tooling setup, component maneuvering, and factory integration.
- Identify, manage, and resolve tooling-related safety, structural, and integration risks before hardware reaches final assembly.
- Support prototype builds, first-of-a-kind hardware integration, factory/field assembly, and hands-on trouble shooting during hardware operations.
Benefits
- Comprehensive health benefits (medical, dental, vision)
- Employee equity stock options
- 20 days PTO
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What This Job Offers
Job Type
Full-time
Career Level
Senior
Education Level
No Education Listed
