Structures Manufacturing Engineer

As a Structures Manufacturing Engineer – Tooling & R&D at Hermeus, you will enable the rapid development, integration, and test of flight-critical structural assemblies through innovative tooling and hands-on manufacturing execution. This role is deeply embedded in early-stage design-build-test cycles, where speed, creativity, and engineering judgment matter as much as formal process.

You will design and build tooling, fixtures, and ground support equipment while partnering closely with structures, test, and manufacturing teams to turn evolving designs into real, testable hardware. This is a highly hands-on role for engineers who like being on the floor, solving problems in real time, and iterating quickly to move flight hardware forward.

As a Structures Manufacturing Engineer – Tooling & R&D at Hermeus, you will enable the rapid development, integration, and test of flight-critical structural assemblies through innovative tooling and hands-on manufacturing execution. This role is deeply embedded in early-stage design-build-test cycles, where speed, creativity, and engineering judgment matter as much as formal process.

You will design and build tooling, fixtures, and ground support equipment while partnering closely with structures, test, and manufacturing teams to turn evolving designs into real, testable hardware. This is a highly hands-on role for engineers who like being on the floor, solving problems in real time, and iterating quickly to move flight hardware forward.

• Own the design, fabrication, and validation of tooling, fixtures, and ground support equipment supporting structural prototype builds, integration, and testing.

• Rapidly iterate tooling concepts to support changing designs, test objectives, and build sequences.

• Partner with structures, manufacturing, and test engineers to define integration flow, tooling interfaces, and build strategies .

• Perform mechanical checks, fit-ups, and hands-on trials to qualify tooling for development and flight hardware builds.

• Maintain configuration control, documentation, and safety standards across evolving tooling systems.

• Support the build, integration, and inspection of primary and secondary structural assemblies for the Quarterhorse vehicle and future platforms.

• Act as the primary interface between design engineers and technicians during prototype and flight hardware builds.

• Identify integration challenges early and develop creative tooling or process solutions to maintain build velocity.

• Provide direct, real-time design feedback based on hands-on build experience.

• Support structural testing campaigns by enabling efficient, repeatable, and safe hardware setups.

• Develop and refine prototype manufacturing processes with a focus on speed, flexibility, and learning.

• Drive continuous improvement of tooling and build approaches to reduce iteration time and increase build quality.

• Resolve non-conformances through hands-on troubleshooting and root cause analysis in collaboration with Quality.

• Coordinate internal and external fabrication resources to meet aggressive R&D and test milestones.
• Experience in an R&D or startup development environment .

• Direct experience designing or building tooling for large structural assemblies .

• Experience supporting a flight development or experimental aircraft program .

• Familiarity with lean prototyping and rapid iteration in low-volume environments.