Design Engineer

Job Overview

At Ledge, we believe outdoor spaces are not just extensions of the home—they're living works of art. As pioneers in the premium in-pool and poolside product design space, our mission is simple yet powerful: to help our customers manifest their identity by elevating their approach to outdoor living.

Key Responsibilities

• Advanced 3D Modeling: Create, edit, and update complex 3D parametric models and engineering drawings for new and existing products using SolidWorks and Rhino.
• In-House CNC & Sheet Design: Design parts and products specifically optimized to be cut from High-Density Polyethylene (HDPE) sheets, maximizing material yield and minimizing waste.
• DFM & DFA Optimization: Apply rigorous Design for Manufacturing (DFM) and Design for Assembly (DFA) principles to all products. Ensure in-house items feature intuitive, efficient, and robust assembly methods.
• Vendor Collaboration: Act as the primary technical point of contact with external tooling and molding vendors. Review tool drawings and make necessary design adjustments (draft angles, wall thickness, parting lines) to achieve a flawless finished goods.
• Prototyping & CNC Programming: Program toolpaths for CNC machines using CAMWorks. Hands-on fabrication, cutting, and assembly of physical prototypes to validate design concepts.
• Testing & Documentation: Perform physical testing on prototypes, track engineering changes, and create highly accurate Bills of Materials (BOMs) and consumer instruction manuals.
• Continuous Improvement: Identify process or design deficiencies in both molded and sheet-routed products, developing engineering solutions to improve quality and throughput.

What Success Looks Like

• Design production-ready products that balance aesthetics, functionality, manufacturability, durability, and cost while maintaining Ledge's premium brand standards.
• Deliver accurate 3D models, engineering drawings, Bills of Materials, and technical documentation that enable efficient production and minimize engineering changes.
• Partner effectively with Product Development, Manufacturing, and external vendors to accelerate product launches, resolve manufacturing challenges, and continuously improve product quality.
• Apply Design for Manufacturing (DFM) and Design for Assembly (DFA) principles to reduce complexity, improve assembly efficiency, and optimize production processes for both in-house and outsourced manufacturing.
• Develop and validate prototypes through hands-on testing, using findings to refine designs and ensure products meet performance, quality, and customer expectations.
• Foster a mindset of continuous improvement by identifying opportunities to enhance product performance, manufacturing efficiency, material utilization, and overall customer experience.

Requirements

• Education: Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, or a closely related field preferred (Associate degree with extensive relevant experience considered).
• Plastics & Molding Expertise: Proven experience designing parts for Injection Molding, Rotomolding, and Blow Molding, with a strong understanding of tooling constraints.
• Sheet Fabrication & Assembly: Experience designing products utilizing CNC routing and mechanical assembly methods.
• CAD/CAM Proficiency: Advanced proficiency in 3D Parametric Modeling and surface modeling (SolidWorks required). Strong working knowledge of CAM software (CAMWorks preferred) for generating CNC toolpaths.
• Vendor & Project Management: Experience collaborating with external toolmakers and internal production teams to troubleshoot manufacturing challenges and refine designs.
• Hands-On Skills: Proficiency with CNC machinery, basic hand tools, and small power tools for prototype fabrication.
• Soft Skills: Effective time management and logical decision-making ability. Excellent communication, leadership and interpersonal skills.

Schedule

Monday – Friday, 8:00 AM to 5:00 PM.

Must be able to lift 75+lbs on a regular basis (with support).

Moving, bending, kneeling, and handling is required.

Benefits

We offer a competitive salary, benefits package, and the opportunity to work with a dynamic team in a positive and supportive work environment.