Staff Tooling Engineer

About Firehawk Aerospace

Firehawk Aerospace is pioneering the development of additively manufactured rocket propulsion systems, combining advanced manufacturing techniques with innovative engineering to deliver safer, more reliable, and cost-effective solutions for space exploration and defense. We are seeking a talented Tooling Engineer to join our team and help shape the future of rocket motor manufacturing.

Job Summary

As a Staff Tooling Engineer at Firehawk Aerospace, you will play a critical role in designing and developing manufacturing equipment and processes for our rocket motor systems. You will work closely with the hardware design, production, and quality teams to ensure efficient, safe, and scalable factory operations. This position requires a hands‑on approach to problem‑solving, a strong understanding of manufacturing principles, and a commitment to continuous improvement.

Key Responsibilities

• Design tooling solutions to support new production lines and R&D efforts, ensuring manufacturability and scalability
• Rapidly develop design concepts using 3D modeling software,
• Provide estimates for tooling projects and support capital budget planning activities
• Support EH&S initiatives for increased safety and ergonomics across all sites and production lines
• Support hardware engineering teams in transitioning products from development to production
• Lead Design for Manufacturing and Assembly (DFMA) initiatives to optimize product designs for manufacturability and efficiency
• Develop and execute validation and qualification plans for new tooling and equipment
• Identify opportunities for process improvements to enhance production efficiency, reduced cycle times, and improved product quality
• Create and maintain tooling documentation, support manufacturing engineers in production planning activities and creation of work instructions
• Collaborate with automation suppliers to ensure that tooling solutions meet technical requirements, quality standards, and delivery schedules
• Ensure tooling and manufacturing processes comply with safety, environmental, and regulatory requirements
• Support routine maintenance and repair planning for factory equipment and tooling
• Support hardware engineering in design and fabrication of test specific tooling and fixtures

Basic Qualifications

• Bachelor’s degree in Mechanical, Manufacturing, Industrial Engineering, or related field
• Minimum of 8 years of experience in manufacturing engineering or production support in defense, or similar industry
• Extensive design experience using 3D modeling software (PTC Creo preferred)
• Experience in conceptual design of complex mechanical assemblies
• Working knowledge of geometric dimensioning and tolerancing (ASME Y14.5)
• Strong knowledge of machining processes and experience interfacing with machine shop personnel
• Advanced knowledge of manufacturing principles, including lean manufacturing, Six Sigma, and Design for Manufacturing and Assembly (DFMA)
• Experience with configuration management and document change control using PTC Windchill
• Experience with manufacturing process documentation, including work instructions and process flow diagrams
• Strong problemsolving skills and the ability to perform root cause analysis and implement corrective actions
• Excellent communication skills, with the ability to work effectively in crossfunctional teams
• Selfstarter who is comfortable working with limited direction
• Ability to travel (up to 10%)

Preferred Qualifications

• Experience in the manufacturing of rockets or weapon systems and components
• Handson integration and manufacturing experience
• Structural analysis experience (ANSYS)
• Experience with safe handling of explosives or other hazardous material
• Proficiency with Deltek Costpoint or similar ERP system
• Experience planning and implementing automation and robotics in manufacturing processes
• Robust knowledge of machine shop processes and equipment, and experience interfacing with machine shop personnel
• Experience transitioning products from development to production
• Certification in lean manufacturing, Six Sigma, or related methodologies.
• Ability to obtain and maintain a DOD issued security clearance

ITAR Requirements

To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.

Work Environment and Physical Requirements

Employees in these positions must possess mobility to work in a standard office setting and to use standard office equipment, including a computer; stamina to sit and to maintain attention to detail despite interruptions; may occasionally lift/carry/push/pull up to 25 pounds; may require minimal walking, standing for extended amounts of time, climbing, crouching, and/or bending; and vision to read printed materials and a computer screen, and hearing and speech to communicate in person and over the telephone. May require the ability to travel by air or auto. May require the use of personal protective equipment such as safety glasses, safety shoes, and shop coat. These positions may be expected to work varying shifts and hours to ensure successful operation of activities in the organization.

Security Clearance

May be required to obtain and maintain a U.S. Security Clearance at the appropriate level. Requires U.S. Citizenship. Must also be able to satisfy federal government requirements for access to government information, and having dual citizenship may preclude you from being able to meet this requirement.

Benefits At Firehawk Aerospace

At Firehawk Aerospace, we are committed to supporting the well-being of our employees and their families. Our comprehensive benefits package is designed to provide peace of mind and help you thrive both personally and professionally.

• Health Coverage: We offer 100% employerpaid medical premiums for employees and up to 75% coverage for dependents under select plans, with additional options for PPO and HDHP plans. Coverage begins the first of the month following your hire date.
• Dental and Vision Plans: Affordable dental and vision plans with extensive coverage options, including preventive care, orthodontics, and allowances for contacts and frames.
• Employee Assistance Program (EAP): Access to free, confidential services, including counseling, legal consultations, wellness coaching, and virtual concierge services to support your worklife balance.
• Flexible Work Schedule: Enjoy a 9/80 schedule option, allowing for greater flexibility and worklife balance.
• OnSite Perks: Complimentary snacks and refreshments to keep you energized throughout the day.
• Professional Growth: Mentorship opportunities with industryleading engineers and engagement in cuttingedge projects at the forefront of aerospace innovation.

Firehawk Aerospace is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or veteran status.