Upholstery Development Engineer III

Upholstery Development Engineer III

Company: Exemplis Department: Product Engineering Location: Buena Park, CA, US, 90620 Cypress, CA, US, 90630 Work Designation: Onsite Salary Range: $112,406.00 - $168,608.00 Position Summary: We are seeking a hands-on and technically skilled Upholstery Development Engineer to support the end-to-end development of upholstered furniture products. As a key member of the Product Development team, you will lead in creating precise upholstery patterns and ensure a seamless transition from prototyping to production. This role requires expertise in pattern development, upholstery construction, and close collaboration with cross-functional teams, including Product Engineering, Manufacturing, and Design. Strong experience in patternmaking, upholstery fabrication, and Design for Manufacture (DFM) principles is essential for success. This is a senior individual contributor role with technical ownership of pattern development standards and approvals. Responsibilities and Essential Functions: Establish pattern development best practices, workflows, & documentation to ensure consistency & efficiency Lead pattern development during product introduction to meet project goals, timelines, quality, ergonomics & aesthetic standards Review preliminary product designs for feasibility & suggest DFM optimizations Collaborate with Engineering & Design to refine foam shapes & densities for optimal fit, comfort, & manufacturability Review & approve patterns for structural integrity, ergonomic performance & manufacturability Interpret design/CAD into production-ready patterns Use software to convert complex 3D surfaces into accurate 2D patterns and supporting sewing documentation Oversee prototype builds & resolve pattern issues related to foam, seams, or fabric tension Recommend product construction adjustments to improve fabric laydown & reduce variability Create & maintain living documents to communicate prototyping challenges & suggestions for improvement Serve as the key escalation point for pattern challenges, driving effective solutions & continuous improvement Use digital patterning, nesting, & grading tools integrated with automated cutting systems Identify cost & process optimization opportunities while maintaining product quality & aesthetics Manage BOMs, revisions, & technical documentation through PLM/PDM systems Create & maintain relevant upholstery & patternmaking standards Qualifications, Skills and Education: Required Qualifications: 5+ years of upholstery patternmaking & fabrication experience, including cut, molded, & over-molded foam applications Hands-on experience with foam, muslin, vinyl, & other upholstery prototyping materials Strong communication & collaboration skills with cross-functional & cross-cultural teams Proven ability to develop & refine complex foam assemblies for consistency & manufacturability Skilled in analyzing foam properties (compression, spring-back, adhesion) & applying insights to pattern design Proficiency in industrial sewing machines, upholstery tools, & prototyping equipment Advanced proficiency in at least one patternmaking software such as Optitex, Gerber AccuMark, Lectra, or ExactFlat Experienced in developing upholstered products from concept through production launch Ability to interpret sketches, CAD drawings, & 3D models into accurate production-ready patterns Preferred Qualifications: Technical certification in Patternmaking or equivalent Experience working with U.S.-based consumer product companies Familiarity with 3D patterning & visualization software (CLO, Browzwear, NX Mastertrim) Knowledge of North American manufacturing & rapid prototyping workflows, especially automotive trim Adaptable, detail-oriented, & proactive in problem solving Experience with cost reduction exercises Bilingual proficiency in English & Spanish (verbal & written) Physical Demands Ability to stand for extended periods & handle upholstery materials, leather, & tools Perks and Benefits: We hope that you're excited by the possibilities that come along with working at Exemplis! With us, TEAM comes first. We bring integrity, passion, and excellence to work each day. Being part of our team means living our core values and thriving in an environment of constant innovation and positive change. In addition to our unique culture, we also offer these fun perks and benefits. Competitive Salary: Our compensation philosophy is to be externally competitive, internally fair, and not win or lose on compensation. Employee Discounts: We offer our employees discounts across all of our product lines. Hit Our Numbers Lunch: When we hit our monthly milestones, we all celebrate! About Us: It all started in a small warehouse in California with just three employees, a fax machine and a bell that rang out every time a chair came down the conveyor belt. 30 years later, Exemplis continues to lead, innovate and disrupt an array of industries through its growing family of brands including SitOnIt Seating, Timbuk2, X-Chair, Maverick, Mavix, Edloe Finch, and Albany Park. From sustainable manufacturing to outreach programs and more, we strive to make a positive impact on everyone we serve. We make sure our people (and their communities) are at the core of our organization. To make a difference, we must be a champion of diversity, inclusion, service and social justice above all else.