Fixture Design Engineer
Boston, MA
Job Description:
The Senior Fixture Design Engineer is responsible for leading the design, development, validation, and deployment of manufacturing fixtures, assembly tooling, inspection fixtures, test fixtures, robotic end-of-arm tooling (EOAT), gauges, jigs, and production aids supporting new product introduction (NPI) and high-volume manufacturing operations.
This role collaborates closely with Product Engineering, Manufacturing Engineering, Quality, Operations, Automation, and Production teams to develop robust tooling solutions that meet evolving product and process requirements. The engineer will drive fixture programs from concept development through detailed design, fabrication, validation, installation, and production launch while coordinating activities across global engineering teams, suppliers, and customers.
The ideal candidate possesses strong mechanical design expertise, manufacturing process knowledge, fixture design experience, and the ability to lead complex tooling projects in a fast-paced manufacturing environment.
Key Responsibilities
Fixture Design & Development
- Lead the design and development of assembly fixtures, inspection fixtures, test fixtures, robotic tooling, handling fixtures, gauges, welding fixtures, jigs, and production aids.
- Gather requirements from Product Engineering, Manufacturing Engineering, Quality, Operations, Automation, Maintenance, and Production teams.
- Translate manufacturing, quality, safety, ergonomic, and product requirements into effective fixture and tooling solutions.
- Develop innovative tooling concepts to improve product quality, process capability, throughput, operator safety, and manufacturing efficiency.
- Support Design for Manufacturing (DFM), Design for Assembly (DFA), and continuous process improvement initiatives.
- Analyze fixture functionality to ensure repeatability, accuracy, durability, and ease of operation.
Mechanical Design Engineering
- Create fixture concepts, detailed 3D models, assemblies, fabrication drawings, and complete design documentation packages.
- Perform concept design, detailed design, and 2D detailing activities using CAD software.
- Develop manufacturing-ready drawings including GD&T, tolerance requirements, BOMs, assembly instructions, and fabrication specifications.
- Conduct tolerance stack-up analysis, fixture locating scheme development, datum structure definition, and dimensional validation.
- Design fixture mechanisms including slides, lift systems, clamps, adjustable units, pneumatic devices, sensor integration, and automation interfaces.
- Validate fixture designs for manufacturability, maintainability, reliability, serviceability, and operator safety.
- Select and integrate standard components including locators, clamps, sensors, actuators, and tooling hardware.
- Perform structural evaluations, payload assessments, and functional verification to ensure tooling meets operational requirements.
Cross-Functional Collaboration
- Lead fixture design reviews with Product Engineering, Manufacturing Engineering, Quality, Operations, and Production teams.
- Collaborate with customers to review tooling concepts, design maturity, validation plans, and manufacturing requirements.
- Present design solutions and incorporate stakeholder feedback throughout the development process.
- Ensure tooling designs meet customer specifications, manufacturing standards, and project objectives.
- Support formal design approvals, drawing releases, and engineering sign-off activities.
Global Engineering Coordination
- Provide technical guidance and requirements to offshore design teams and global engineering resources.
- Review concepts, 3D models, drawings, and technical documentation generated by remote teams.
- Resolve design issues and ensure compliance with engineering standards and customer requirements.
- Coordinate project activities to ensure on-time delivery of tooling programs.
Supplier & Tool Build Management
- Partner with tooling suppliers, machine shops, fabrication vendors, and automation integrators.
- Review supplier quotations, technical proposals, fabrication methods, and project schedules.
- Support fixture fabrication, assembly, inspection, buyoff, and acceptance activities.
- Troubleshoot manufacturing and assembly issues during tooling build and implementation.
- Monitor supplier performance related to quality, cost, and delivery objectives.
- Conduct tooling acceptance reviews, factory acceptance testing (FAT), and production readiness assessments.
Validation & Production Launch
- Support prototype builds, engineering builds, pilot production, and manufacturing launches.
- Oversee fixture installation, commissioning, debugging, and process validation activities.
- Conduct fixture qualification, capability studies, repeatability evaluations, and dimensional verification.
- Support APQP, PPAP, PFMEA, Control Plans, process validation, and production readiness activities.
- Drive corrective actions and tooling improvements based on validation and production feedback.
Continuous Improvement
- Identify opportunities to improve tooling reliability, performance, maintainability, and manufacturing efficiency.
- Support engineering change management and fixture modifications resulting from product or process changes.
- Develop and maintain operating procedures, maintenance instructions, spare parts lists, and technical documentation.
- Mentor junior engineers and designers while promoting standardized fixture design methodologies and best practices.
Basic Qualifications
- Bachelor''s degree in Mechanical Engineering, Manufacturing Engineering, Mechatronics Engineering, Robotics Engineering, or a related technical discipline.
- 7+ years of experience in fixture design, tooling design, manufacturing engineering, automation tooling, or production equipment development.
- Strong experience in concept design, detailed 3D modeling, and 2D detailing of manufacturing fixtures and tooling systems.
- Proficiency with CAD software such as SolidWorks and AutoCAD.
- Experience creating fabrication drawings, assembly drawings, BOMs, and GD&T documentation.
- Strong understanding of machining, fabrication, welding, assembly, inspection, and manufacturing processes.
- Experience working in cross-functional engineering and manufacturing environments.
- Ability to manage multiple projects and priorities simultaneously.
Preferred Qualifications
- Experience supporting New Product Introduction (NPI), manufacturing launches, and industrialization programs.
- Experience coordinating with offshore design teams and global engineering organizations.
- Strong knowledge of fixture locating principles, datum structures, dimensional control, and tolerance analysis.
- Experience designing automation-ready fixtures, EOAT, robotic tooling, and sensor-integrated systems.
- Familiarity with APQP, PPAP, PFMEA, Control Plans, MSA, and production validation methodologies.
- Experience managing tooling suppliers, fabrication vendors, and equipment procurement activities.
- Knowledge of machine safety standards, ergonomics, and manufacturing risk assessments.
- Experience with PLM systems such as Teamcenter, Windchill, or Enovia.
Key Skills & Competencies
- Advanced fixture and tooling design expertise.
- Strong mechanical design and manufacturing process knowledge.
- Proficiency in GD&T, tolerance stack-up analysis, and dimensional validation techniques.
- Ability to convert evolving product and manufacturing requirements into practical tooling solutions.
- Strong customer-facing communication, presentation, and design review skills.
- Effective project leadership and stakeholder management capabilities.
- Experience leading global engineering collaboration and offshore design coordination.
- Strong problem-solving, root-cause analysis, and continuous improvement mindset.
- Ability to manage multiple tooling programs in a fast-paced manufacturing environment.
- High attention to detail with a focus on quality, safety, manufacturability, reliability, and cost optimization.
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