Tooling Engineer

About the role

This role focuses on developing, designing, analyzing, and implementing custom tooling and equipment used to assemble and test a constellation of Low Earth Orbit satellites. The Tooling Engineer supports the full lifecycle from research and development through design validation and into production, converting cross-functional requests into tooling systems that are easy to use, cost-effective, accurate, and robust. This position operates in a fast-paced, highly collaborative environment and offers the opportunity to work with technical leaders while continuously improving product performance, quality, and cost.

Responsibilities

• Develop, design, and implement custom tooling and equipment for satellite assembly and qualification/acceptance testing (QTP/ATP).

• Convert requirements and requests from various engineering and manufacturing teams into practical, user-friendly, and cost-effective tooling solutions.

• Create detailed 3D CAD models, drawings, and documentation for complex tooling systems, fixtures, and mechanisms.

• Perform structural analysis of tooling and fixtures using both hand calculations and Finite Element Analysis (FEA) to ensure stiffness, strength, and reliability.

• Plan and manage tooling projects, including defining scope, estimating costs, developing schedules, and tracking progress against milestones and budgets.

• Support and oversee the fabrication of tooling, working closely with internal and external fabrication resources to ensure quality and manufacturability.

• Collaborate with cross-functional teams to solve complex problems that span multiple technical domains and manufacturing disciplines.

• Coordinate and participate in the testing, commissioning, and validation of tooling in the manufacturing environment to ensure safe, effective, and repeatable operation.

• Design and refine mechanisms, bolted and welded structures, assembly fixtures, alignment fixtures, test fixtures, rigging solutions, and material handling tools.

• Apply mechanical engineering fundamentals to address structural dynamics, weldments, and bolted joint design for tooling and fixtures.

• Utilize practical knowledge of manufacturing processes, materials, and rapid prototyping techniques to optimize tooling design and fabrication.

• Incorporate feedback from production and test operations to iterate and enhance tooling usability, safety, and robustness.

• Support adherence to export control requirements by ensuring compliance with applicable laws and regulations related to project work.

Essential Skills

• Bachelor’s degree in mechanical engineering or relevant equivalent experience.
• 3+ years of experience with CAD design of complex systems, including 3D modeling and detailed drawings.
• 3+ years of experience performing structural analysis, including hand calculations and Finite Element Analysis (FEA).
• 1+ years of experience with project management, including scheduling and budgeting responsibilities.
• Hands-on fabrication experience with mechanical components, fixtures, or tooling.
• Proficiency with CAD tools for 3D modeling, preferably Siemens NX.
• Experience designing mechanisms, fixtures, and structural components for complex mechanical systems.
• Strong knowledge of mechanical engineering fundamentals, including stiffness, strength, structural dynamics, weldments, and bolted structures.
• Ability to translate functional requirements into practical, manufacturable tooling and equipment.
• Demonstrated ability to work in a fast-paced, intellectually challenging environment while maintaining high standards for quality and performance.

Additional Skills & Qualifications

• Experience designing tooling solutions specifically for aerospace hardware.
• Strong background in the design of mechanisms, bolted and welded structures, assembly fixtures, alignment fixtures, test fixtures, rigging solutions, and material handling equipment.
• Practical knowledge of manufacturing processes and materials commonly used in assembly tooling and rapid prototyping.
• Experience using Siemens NX for 3D modeling and Simcenter 3D for FEA simulation.
• Laser tracking experience for alignment or metrology applications is a plus.
• Formal training or certification in Operational Excellence systems such as Lean, 5S, or Six Sigma is a plus.
• Demonstrated ability to apply critical thinking and sound engineering judgment in complex and ambiguous situations.
• Entrepreneurial mindset with the ability to wear many hats and contribute across multiple technical and operational domains.
• Strong collaboration and communication skills to work effectively with cross-functional teams and technical leaders.