Design Engineer - PPE Soft Goods Developer

We are seeking an experienced Soft Goods Design Engineer to lead the development of innovative life-safety equipment for the professional rope rescue, rope access, work-at-height, and technical rescue markets. This role will be responsible for the design, prototyping, testing, validation, and production launch of textile-based products including harnesses, positioning belts, gear bags, packs, lanyards, and specialized load-bearing equipment used in critical life-safety applications.

The ideal candidate has a strong background in soft goods product development (PPE, harnesses, straps, bags) and is comfortable working across the entire product lifecycle—from concept generation and prototype fabrication through testing, certification, manufacturing implementation, and product launch. This individual will regularly create and sew prototypes, conduct structural and dynamic testing, generate technical documentation, and drive cross-functional design reviews while ensuring products meet stringent safety, performance, and manufacturability requirements.

This position requires a hands-on engineer who enjoys building, testing, and continuously improving products that life-saving professionals trust with their lives.

Essential Responsibilities

Product Design & Development

• Lead the design and development of soft goods products (harnesses, belts, etc.) and textile-based systems for rope rescue, rope access, and work-at-height applications.
• Develop innovative solutions that balance performance, durability, ergonomics, manufacturability, weight, and cost.
• Drive projects from concept through production release while meeting schedule and business objectives.
• Develop detailed product specifications and engineering requirements.
• Evaluate competitive products, field feedback, and emerging technologies to guide product innovation.
• Mentor junior engineers and provide technical leadership on soft goods development projects.

Prototyping & Fabrication

• Create, modify, and refine prototypes using industrial sewing equipment and related fabrication tools.
• Develop prototype harnesses, belts, bags, load-bearing textile assemblies, and integrated textile-hardware systems.
• Establish construction methods, stitch patterns, reinforcement strategies, and assembly techniques.
• Iterate designs rapidly based on testing results and stakeholder feedback.

Testing & Validation

• Plan and execute laboratory and field-testing activities.
• Operate drop towers, tensile test machines, cyclic loading equipment, and custom test fixtures.
• Develop and validate test methods and acceptance criteria.
• Analyze structural performance, durability, and failure modes.
• Generate comprehensive test reports and present results to stakeholders.
• Support third-party certification testing and compliance efforts.

Technical Documentation

• Develop and maintain engineering documentation including: 
  • Tech Packs
  • Bills of Materials (BOMs)
  • Product Specifications
  • Construction Drawings
  • Manufacturing Instructions
  • Design Verification Plans and Reports
  • Test Reports
  • Risk Assessments
  • Engineering Change Documentation
• Create technical presentations to communicate project status, design decisions, testing results, and recommendations.
• Ensure documentation packages are complete and production-ready for manufacturing partners.

Manufacturing & Supplier Support

• Collaborate with domestic and international manufacturing partners to optimize product quality and production efficiency.
• Support pilot builds, production launches, and process validation activities.
• Review manufacturing samples and first articles for compliance with engineering requirements.
• Investigate product quality issues and implement corrective actions.
• Drive Design for Manufacturing (DFM) improvements and cost-reduction initiatives.

Cross-Functional Leadership

• Lead formal design reviews throughout the product development process.
• Collaborate with Product Management, Quality, Operations, Marketing, and Supply Chain teams.
• Participate in risk assessments, failure investigations, and continuous improvement initiatives.
• Support customer evaluations, field trials, and user feedback sessions.
• Present technical recommendations and project updates to management and executive stakeholders.

Required Qualifications

• Bachelor's degree in Mechanical Engineering, Textile Engineering, Product Design Engineering, Industrial Design, Manufacturing Engineering, or a related technical discipline or demonstrated equivalent technical knowledge.
• 5+ years of product development experience, (DE II) including meaningful experience designing and developing soft goods products.
• Demonstrated experience taking products from concept through production.
• Experience creating and interpreting technical documentation and manufacturing packages.
• Proficiency with CAD software such as SolidWorks, Fusion 360, or equivalent.
• Hands-on prototype fabrication and sewing experience.
• Experience planning and conducting engineering testing programs.
• Strong project management and organizational skills.
• Excellent written, verbal, and presentation skills.
• Proficiency with MS Office tools, especially EXCEL

Preferred Qualifications

• 7–10+ years of experience (DE III) designing technical soft goods products.
• Experience with PPE, industrial safety equipment, climbing equipment, rescue gear, military/tactical products, outdoor equipment, or load-bearing textile systems.
• Deep understanding of: 
  • Webbing and textile materials
  • Sewn construction techniques
  • Foam and spacer materials
  • Load path design
  • Hardware integration
  • Pattern development
• Experience operating industrial sewing machines and prototype fabrication equipment.
• Familiarity with ANSI, NFPA, OSHA, CSA, CE, EN, or other life-safety standards.
• Experience conducting dynamic drop testing and structural load testing.
• Working knowledge of DFMEA, PFMEA, risk analysis, and quality systems.
• Rope access, rescue, climbing, industrial work-at-height, or technical outdoor experience

Desired Characteristics

• Passion for developing outdoor safety equipment that protects and saves lives.
• Hands-on engineer who enjoys building and testing products.
• Strong analytical and problem-solving skills.
• Comfortable working in both workshop and laboratory environments.
• High attention to detail and commitment to quality.
• Self-starter capable of leading projects with minimal supervision.
• Collaborative team player with strong leadership potential.
• Ability to balance engineering rigor with practical product development timelines