Sr. Tool Design Engineer
About The Position
The Sr. Tool Design Engineer is responsible for developing the tools, equipment and processes for the in-house manufacturing, assembly, and testing of electric propulsion systems for aerospace applications. The primary focus of this role is on New Product Introduction (NPI) from initial design stages through entry-into-service. This includes coordination with Design & Quality Engineering, using Solidworks to interpret models & drawings, and ultimately to design the required manufacturing, assembly, and testing tools. In addition, they are responsible for driving new technology and process improvement ideas to advance the company to be a world class manufacturing center. This is a hands-on role that works closely with assembly technicians throughout the NPI and production process and actively supports shop day-to-day execution. This role owns tooling and equipment; manufacturing process development, production documentation, and ERP manufacturing data are owned by the Manufacturing Engineer. Tooling programs span the full production ramp, progressing from manual first-article tooling to rate tooling with significant automation content as magniX industrializes toward higher production volumes, across multiple powertrain product lines. This position requires a candidate who can be productive on tooling concepts and designs with minimal onboarding.
Requirements
- B.S. in Mechanical Engineering
- 5 years of experience as a tooling design engineer (or similar role) in electric motors, aerospace manufacturing, or related industry
- CAD modeling software experience, Solidworks preferred
- Knowledge of assembly processes, rapid prototyping, fabrication, and tool design
- Proficiency in GD&T (ASME Y14.5) and tolerance stack-up analysis
- Demonstrated ability to take tooling from concept through validated hardware with minimal onboarding support
- Familiarity with manufacturing equipment and quality assurance techniques
Nice To Haves
- Tooling experience specific to electric motor assembly: press and shrink fits, heat-assisted assembly, stator and rotor handling, winding support, balancing, potting/encapsulation, and heavy-component lift and handling fixtures
- Experience with semi-automated assembly cells, pneumatic and servo-driven fixturing, and error-proofing (poka-yoke)
- Six Sigma and 5S familiarity
- Experience designing tooling to AS9100 quality system requirements
- Familiarity with FAA regulatory environment
- Commitment to health & safety standards and environmental regulations
Responsibilities
- Design, procure, install, and validate tooling and equipment
- Propose, develop, and test effective automated, semi-automated, and manual systems, including the progression from manual first-article tooling to rate tooling with significant automation content
- Perform tolerance stack-up analysis and apply GD&T to ensure tooling holds critical assembly characteristics such as concentricity, runout, bearing fits, and rotor-to-stator air gap
- Participate in the design review process, including design for manufacturing and assembly
- Troubleshoot and resolve issues and delays in production
- Find ways to reduce assembly time/cost and improve quality through tooling or equipment
- Define, justify, and schedule the tooling and capital equipment investments required to support planned production rate increases
- Develop tooling cost estimates and lead times to support ROM program estimates and capital planning
- Manage tooling vendors and machine shops through quoting, fabrication, inspection, and acceptance
- Design inspection fixtures and gages in coordination with Quality, including support for gage R&R
- Collaborate with Design Engineering, Quality, Supply Chain, and Test teams
Benefits
- 100% company-paid premiums for medical, dental, and vision insurance (for employees & dependents)
- 4 weeks paid vacation + 1-week annual end-of-year shutdown, sick time, and 11 paid holidays
- 401K retirement plan with industry leading 9.5% company contribution
- Company paid Life insurance, AD&D, Short-Term and Long-Term disability insurance
- Catered lunches and quarterly company fun-day events!
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What This Job Offers
Job Type
Full-time
Career Level
Senior
