Design / Tooling and Manufacturing Engineer

PCX Aerostructures, LLC; Santa Ana (CA); On-site; USD 125,000 - 150,000; Full time

Job summary

Applied Aerospace & Defense, located in Santa Ana, seeks a Design / Tooling and Manufacturing Engineer to design production tooling, fixtures, and processing aids using advanced CAD and MBd techniques to ensure robust, cost-effective manufacturing processes.

You will collaborate across engineering, manufacturing, quality, and production teams, lead design reviews, and apply lean design principles to tooling and manufacturing design.

Qualifications

• 10+ years aerospace tooling design experience.
• Strong knowledge of GD&T per ASME Y14.5.
• Ability to lead cross-functional engineering reviews.
• Experience with NPI and production tooling development.

Responsibilities

• Create detailed tooling designs, fixtures, and processing aids using CAD modelling, GD&T, and tolerance analysis from inputs.
• Generate derivative/secondary models, reference geometry, and tooling datasets for NC programming, inspection, assembly, and test.
• Develop layout and facility-related design elements to support production and workflow optimization.
• Validate tooling and design intent through engineering analysis, producibility reviews, and shop floor application.
• Present design status, metrics, engineering recommendations, and conduct design reviews to internal teams.
• Lead root cause investigations and implement corrective actions to improve design robustness and manufacturability.

Skills

3D CAD modelling

GD&T proficiency

MBD workflows

Root cause analysis

Cross-functional collaboration

Education

Bachelor's degree in mechanical engineering

Tools

CAD software

Tolerance analysis tools

Job description

Design / Tooling and Manufacturing Engineer

Applied Aerospace & Defense (Applied) is a premier provider of advanced design, engineering, and vertically integrated manufacturing solutions for leading and next-generation space and defense technology companies. Applied builds complex hardware for extreme operating environments and is focused on three core markets: Space and Launch Systems, Defense Aviation and Airborne Systems, and C5ISR and Precision Strike Systems. With decades of space and defense manufacturing heritage, Applied combines deep material science and IP-enabled process expertise with the ability to enable rapid prototyping, enhance new product development, and responsively scale production. Across its nationwide infrastructure of advanced manufacturing facilities, Applied continuously supports a balanced mix of next-generation technology and platform development, large scale production programs, and aftermarket sustainment for enduring platforms.

Applied Aerospace and Defense is an equal opportunity employer.

The Design Engineer is responsible for the design, development, and technical validation of production tooling, derivative models, processing aids, and various engineering design deliverables required to support aerospace manufacturing. This role integrates advanced CAD modeling practices, model-based definition, GD&T, tolerance analysis, and manufacturing engineering principles to ensure robust, repeatable, and cost-effective production processes. The engineer supports both sustaining production and New Product Introduction (NPI) through high-fidelity technical design work.

Pay Range: $125,000.00 to $150,000.00 per year, depending on experience

Position Summary

The Design Engineer will work collaboratively across engineering, manufacturing, quality, and production teams to deliver manufacturable design solutions that support day-to-day operations and long-term business objectives. The position is responsible for defining and creating designs (3D models, assemblies, drawings, engineering documents) from supplied concepts, sketches, models, or verbal input; ensuring compliance with design standards; validating shop floor application; and resolving problems through structured, engineering-based approaches - ensuring alignment with internal design standards, aerospace industry requirements, and process capability.

Position Requirements

• Create detailed tooling designs, fixtures, and processing aids using CAD modeling, GD&T, and tolerance analysis based on inputs (concepts, sketches, models, verbal input) from other functional groups.
• Generate derivative/secondary models, reference geometry, and tooling datasets for NC programming, inspection, assembly, and test.
• Develop layout and facility-related design elements to support production and workflow optimization
• Validate tooling and design intent through engineering analysis, producibility reviews, and shop floor application
• Interpret engineering models, specifications, and MBD datasets to produce compliant tooling and design solutions.
• Apply/enforce design standards, configuration control, and documentation practices.
• Present design status, metrics, engineering recommendations, technical reports, and conduct design reviews to internal teams
• Resolve complex manufacturing/design issues using structured methods such as 8D, RCCA, or DMAIC.
• Lead root cause investigations and implement corrective actions to improve design robustness and manufacturability.

Additional responsibilities include:

• Apply lean design, ergonomic requirements, and continuous improvement to tooling and engineering design processes.
• Partner with cross-functional teams on cost-out, time reduction, and simplification projects using engineering analysis.
• Own configuration management, revision control, and technical accuracy of tooling models and drawings.
• Support assembly, test, machining, and inspection tooling design across multiple product families.

Minimum Qualifications

• 10+ years of aerospace tooling design, mechanical design, or advanced 3D CAD modeling experience (tooling, fixtures, assemblies, or manufacturing equipment).
• 5+ years of hands on manufacturing engineering experience in an aerospace production environment.

Desired Characteristics

• Bachelor's degree in mechanical engineering, manufacturing engineering, design engineering, or related technical field.
• Proficiency in complex 3D modeling, multi-body design, surfacing, large assemblies, and detailed drawing creation.
• Strong working knowledge of GD&T per ASME Y14.5 and familiarity with model-based definition (MBD) workflows.
• Proven ability to analyze design feasibility, manufacturability, tolerance interactions, and production variation.
• Strong communication skills for technical presentations, design reviews, and cross-functional collaboration.
• Demonstrated leadership in driving engineering design projects, coordinating multiple tasks, and managing technical priorities.
• High proficiency in structured problem-solving and engineering root cause analysis methods

Physical Requirements (Lifting, Walking, Bending, Stooping kneeling etc)

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this Job, the employee is regularly required to sit, walk, talk or hear. The employee is frequently required to use hands to handle product and/or components related to process. The employee is occasionally required to stand and reach with hands and arms. The employee must occasionally lift and/or move up to 25 pounds.

Shift: First

Full-Time/Part-Time: Full-Time

Location: Applied Aerospace & Defense, Santa Ana

Category: Engineering

Req Number: ENG-26-00018

Position: Design / Tooling and Manufacturing Engineer

Post Internal Days: 0

Number of Openings: 1

Exempt/Non-Exempt: Exempt