Senior Tooling Design Engineer

ABOUT THE ROLE
As a Senior Tooling Engineer, you will play a critical role in bridging design and production by developing high-quality, robust tooling and fixturing solutions that enable efficient, repeatable, high-rate, and safe manufacturing of complex aircraft structures and systems. You’ll be deeply embedded in the production floor and work cross-functionally with engineering, manufacturing, supply chain, and quality teams to design, validate, and implement tooling and fixturing that supports new product introduction and rate production.
WHAT YOU'LL DO

• Own the design and develop of complex production assembly fixturing, tooling, jigging, machining fixturing, and manufacturing aids to support composite and metallic airframe major assembly as well as part fabrication and sub-assembly.
• Collaborate with manufacturing, design, quality, and supply chain teams to align tooling solutions with product needs and production goals.
• Evaluate and select appropriate materials, components, fabrication methods, and vendors for assembly fixturing and composite part tooling based on cost, timeline, and performance criteria.
• Oversee the procurement, build, commissioning, and validation of assembly fixturing and tooling from internal or external sources.
• Lead tooling trials and validations, including operator evaluations and integration testing on the manufacturing floor.
• Conduct detailed tolerance stack-up and GD&T analysis of assemblies and their subsequent fixturing and tooling to ensure fit, function, and repeatability across production stages.
• Support root cause analysis and corrective action implementation related to tooling or assembly non-conformances.
• Provide real-time manufacturing floor support, resolving fixturing and tooling related issues and collaborating with technicians and engineers to improve production processes.
• Ensure compliance with ergonomic, safety, quality, and aerospace regulatory standards throughout all fixturing and tooling designs and implementations.

REQUIRED QUALIFICATIONS

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Aerospace Engineering, or a related technical field.
• 8+ years of experience aircraft tooling and assembly fixturing design, manufacturing engineering, procurement, setup, and verification to support high-rate production.
• Strong proficiency in CAD software with specific emphasis on complex fixturing and tooling design.
• Hands-on experience supporting assembly fixturing and tooling full life cycle development through design, procurement, build, and implementation.
• Expertise with high-performance airframe manufacturing and assembly processes, including composite and metallic part machining, locating, fixturing, fastening, joining, fuel sealing, and integration from piece part to completed airframe.
• Expertise in modeling, creating GD&T drawings, and performing detailed tolerance stackup analysis for complex assembly fixturing and tooling.
• Eligible to obtain and maintain a U.S. security clearance.

PREFERRED QUALIFICATIONS

• 15+ years of experience in complex aircraft assembly fixturing and tool design supporting high-rate, low-cost rate production.
• Proficiency in Siemens NX and Teamcenter PLM systems.
• Broad experience in leading tooling and manufacturing of composite and metallic airframes and parts.
• Experience in full size determinant assembly.
• Experience in systems integration during airframe assembly.
• Experience in metrology verification methods and equipment used for aircraft assembly fixturing and part fabrication.
• Familiarity with simulation tools to assess tooling performance and ergonomics.
• Demonstrated passion for aviation, aerospace, or unmanned systems through hands-on projects, certifications, or hobbies.
• Active U.S. Secret clearance.