Tool Engineer

Structural Analysis EngineerPrimary Responsibilities: Perform structural analyses for assigned tooling and production equipment, including static, fatigue, vibration, dynamic, and thermal evaluations, per SOW deliverables. Build, validate, and deliver FEA models and hand calculation backups that demonstrate structural integrity and support design decisions. Produce formal stress analysis packages and final reports that document assumptions, loads, boundary conditions, material data, margins, and acceptance criteria. Create and maintain versioned deliverables: model files, input decks, mesh controls, post processing outputs, and annotated CAD interfaces. Participate in design reviews, milestone reviews, and production readiness reviews; present analysis results and address client review comments within agreed response timelines. Investigate tooling discrepancies, failures, or unexpected behavior; perform root cause analysis and provide documented corrective actions and dispositions. Develop and maintain reusable stress templates, calculation guides, checklists, and procedures to standardize tooling analysis practices for the tooling community. Coordinate with cross functional teams (tooling designers, welding, composites, mechanical, lifting/design for safety, controls) to ensure analysis inputs and outputs support integrated tooling solutions. Ensure deliverables meet contractual acceptance criteria and hand off editable models/reports per client configuration and repository requirements. Perform knowledge transfer activities at defined milestones and contract closeout: walkthroughs of models, assumptions, and procedures; transfer of editable files and verification artifacts. Follow client contractor onboarding, site safety, export control, and data handling procedures; complete any required trainings prior to work on site or client systems.Required Skills: Bachelor's, Master's, or Doctorate in engineering, physics, mathematics, or a related technical discipline from an accredited program. Minimum 2 years' experience performing structural analysis (static or fatigue) on tooling, fixtures, equipment, or structural members. Experience building or reviewing 3D CAD models (e.g., CATIA, Creo/ProE, AutoCAD) to derive geometry and interfaces for analysis. Experience producing clear technical reports documenting assumptions, boundary conditions, loads, material properties, and acceptance criteria. Proficiency with standard office tools (Microsoft Office or equivalent) and basic configuration/version control practices. Strong written and verbal communication skills; demonstrated ability to present technical results to engineering and production audiences. Eligible to work as a contractor under the SOW and perform on client premises as required.Preferred Qualifications: Mid / Senior experience thresholds: 5+ years related experience (or equivalent). 3+ years' experience with FEA tools such as Altair HyperWorks, Abaqus, Nastran, Ansys, or equivalent; demonstrated model validation practices. 3+ years' experience with CATIA or equivalent solid modeling tools focused on tooling. 5+ years' experience in Tooling Stress Engineering or production tooling support preferred. Familiarity with welding, below the hook lifting gear, mechanical/hydraulic/pneumatic systems, and composites as applied to tooling assemblies. Experience working to industry standards, hardware codes, and safety requirements; ability to document compliance and margins. Experience developing stress templates, guidebooks, or procedures for engineering teams. Prior contractor experience supporting aerospace production programs and performing formal handoffs of analysis deliverables to host engineering organizations. Demonstrated track record of resolving production tooling issues, improving tooling safety/usability, or reducing rework through engineering analysis.