Tooling Engineer, Forging, Special Projects

The factories-as-a-service team analyzes our current customers' production and supply chain challenges, builds data-driven presentations, designs and scopes factories of the future, and assists the Federal and Strategic sales team in forming long-term partnerships with the DOD, Primes, and other manufacturers.

This team is responsible for scoping, design, cost, schedule, and technology analysis, as well as proposals for major programs and manufacturing transformations across all manufacturing methods and domains.

With several major programs in flight, we are hiring rapidly for this team that will effectively analyze, design, scope, plan, and handover (or join) execution of large-scale manufacturing efforts.

- Design structural and mechanical forge tooling for ferrous and non-ferrous aerospace components and assemblies for the complete suite of forging processes, focusing on mechanical, hydraulic, screw, and horizontal hot forming presses.

- Collaborate with engineers and vendors to source/build, and deploy forge tooling systems.

- Interface with technicians to validate, install, and optimize forge tooling usage

- Conduct FEA, flow simulations, and die stress analyses to validate designs

- Document technical specifications, usage guides, and safety procedures

- Drive testing, validation, and iteration of forge tooling solutions

- Lead efforts to commission custom production forge tooling and machinery

- Support automated forge tooling integration in collaboration with controls engineers, for the exchange of perishable tooling and changeover.

- Use hand calculations and analytical techniques to guide design

- Ensure all systems comply with OSHA and critical lifting requirements

- Bachelor’s degree in Engineering, Aerospace, Physics, or a related STEM field.

- 5+ years in a forging production system environment with emphasis on rate production optimization, tool life improvement, and defect prevention.

- Strong understanding of the various forge manufacturing processes and first principles of bulk deformation for ferrous and non-ferrous products, and how forge tooling supports quality and production efficiency.

- Experience in designing forge tooling systems for complex and high production parts and their integration with larger assemblies and downstream operations, such as machining or welding.

- Ability to contribute to both prototyping and continuous improvement efforts.

- Demonstrated ability to perform FEA and die stress analysis to validate forge tooling under real-world conditions with proficiency in 3D modeling and simulation tools (e.g., SolidWorks, CATIA, NX, ANSYS, DEFORM, Forge, Q-Form, or related software).

- Knowledge of tool steel selection, fabrication, heat treatment, and assembly techniques suitable for high-load and high-temperature environments.

- Knowledge of material behavior for hot bulk forming processes, such as upsetting and extrusion of ferrous and non-ferrous metals.

- Experience working with cross-functional teams including design, quality, and automation.

- 5+ years in a high production forging environment with emphasis on rate production optimization, tool life improvement, and defect prevention.

- Industry experience with critical operations such as designing for assembly, OSHA requirements, and essential considerations of lifting, rotating, and handling of hot tooling assemblies.

- Industry experience with tool steels for hot working, heat treatment, and coatings, as well as tool performance under high heats and loads with an understanding of thermal cycling and efficiency of changeover.

- Industry experience working and interacting within a multidisciplinary team, including engineers, technicians, suppliers/vendors, and facility personnel.