Tools Design Engineer

Role Overview :

We are looking for a Tool Design Engineer to support the design, development, validation, and commissioning of tooling solutions for aerospace manufacturing.

The role involves designing jigs, fixtures, handling tools, lifting tackles, inspection gauges, and test fixtures for composite and metallic aerospace components, while working closely with cross-functional teams to ensure tooling quality, safety, and production readiness.

Key Responsibilities :

• Design and develop tooling for composite and metallic aerospace components, including jigs, fixtures, handling tools, lifting tackles, gauges, and test fixtures.
• Manage the complete tooling lifecycle from concept, design, fabrication, validation, commissioning, FAI prove-out, and production handover.
• Develop tooling solutions for CFRP/GFRP composite manufacturing processes and metallic part manufacturing.
• Perform design risk assessments and apply FMEA methodologies.
• Conduct root cause analysis using 5-Why, Fishbone, and other structured problem-solving methods.
• Prepare tooling documentation including user manuals, work instructions, maintenance manuals, and inspection procedures.
• Collaborate with Manufacturing, Methods/Process Engineering, Quality, CAD & Configuration, Operations, and SCM teams.
• Coordinate with tooling fabrication teams for in-house manufacturing and realization of tooling.
• Troubleshoot tooling-related issues and ensure tooling readiness for continuous production.
• Perform analytical stress calculations and FEA/static structural analysis for tooling designs.
• Ensure tooling complies with applicable ISO standards, aerospace requirements, and safety guidelines.
• Support tooling inspection, qualification, validation, and GR&R studies before release to production.
• Ensure timely completion of tooling deliverables and effective handover to production.

Quality & Compliance :

• Maintain tooling documentation and traceability to support AS9100 audits and customer source inspections.
• Work with Quality teams to address tooling-related NCRs, root cause analysis, and corrective actions.
• Ensure tooling meets required quality, safety, functional, and qualification requirements.

Required Qualifications & Skills :

• B.E./B.Tech in Mechanical or Production Engineering & Preferred Postgraduate qualification/specialization in Tool Design, preferably from CITD or NTTF
• 3–5 years of overall experience with minimum 3 years of relevant tooling experience.
• Experience in tooling design/development in aerospace, automotive, wind energy, heavy engineering, or similar industries.
• Strong knowledge of jigs, fixtures, handling equipment, gauges, and manufacturing tooling.
• Proficiency in CAD software such as NX, SolidWorks, or Creo.
• Strong knowledge of tooling design and manufacturing processes.
• Experience in stress analysis and FEA – Static Structural Analysis.
• Knowledge of FMEA, RCA, 5-Why, and Fishbone analysis.
• Knowledge of ISO standards, aerospace quality requirements, and safety standards.
• Good understanding of tooling inspection, qualification, validation, and GR&R.
• Strong problem-solving and cross-functional collaboration skills.