Manufacturing & Tooling Development Engineer III

Honeybee Robotics a member of the Blue Origin family of companies has been at the forefront of robotics for over 40 years. Our Colorado-based Motion Control Business Unit designs manufactures and tests high-performance motion control components and integrated solutions from actuators and gearboxes to motors and precision control systems for NASA defense and commercial programs including NASAs Artemis I Mission and the Roman Space Telescope.

Blue Origin is seeking an experiencedManufacturing & Tooling Development Engineer IIIto lead the design development and validation of assembly tooling fixtures and aids supporting the build and integration of complex precision mechanical assemblies. You will serve as the technical authority for assembly tooling and fixturing across the product lifecycle from early design engagement through production implementation driving build quality assembly repeatability and schedule performance in support of high-volume production forTeraWavemotion control products.

Responsibilities

Assembly Tooling & Fixture Design

• Lead the end-to-end design and development of assembly fixtures build aids handling fixtures installation tools and torque tooling for complex precision mechanical assemblies including actuators gearboxes motors and integrated motion control units

• Define assembly fixture requirements based on component geometry assembly sequence interface constraints and production rate needs; generate complete tooling design packages including 3D models detailed drawings BOMs and acceptance criteria

• Apply sound locating clamping and datum referencing principles to ensure assembly fixtures deliver repeatable process-capable builds across production volumes and operator skill levels

• Design tooling solutions that support manual semi-automated and potentially robotic assembly operations including part presentation fixtures press and insertion aids alignment fixtures and subassembly holding fixtures

• Design handling and transportation fixtures to protect sensitive assemblies and subassemblies during build and inspection operations

• Evaluate and select tooling materials coatings and construction methods appropriate for the expected wear life assembly environment and production cycle requirements

Tooling Validation & Qualification

• Develop and execute formal assembly tooling validation plans including dimensional verification fit checks assembly runoff studies and repeatability assessments prior to production release

• Define and document acceptance criteria for new and modified assembly tooling; generate tooling qualification reports summarizing validation results and production readiness disposition

• Collaborate with quality engineering to ensure assembly fixtures and gauging solutions are metrologically sound and support traceability to inspection and assembly requirements

• Perform or support first article build events using new tooling to verify that fixtures achieve intended assembly outcomes before full production release

• Identify and resolve assembly tooling nonconformances wear patterns or repeatability issues encountered during production; implement corrective actions and document lessons learned

GD&T & Drawing Review

• Review engineering drawings and 3D models for GD&T compliance per ASME Y14.5 with particular emphasis on datum selection feature control frame applicability and tolerancing strategies as they relate to assembly fixture design and build process requirements

• Advise design engineers on datum structure and tolerancing strategies that support practical cost-effective assembly fixture and gauging solutions and ensure that critical assembly interfaces aretolerancedto achieve functional fit and performance requirements

• Identify drawing ambiguities tolerance conflicts or features that create undue assembly tooling complexity or build variation risk; initiate formal drawing change requests in collaboration with design engineering

• Apply tolerance stack-up analysis (1D/2D/3D) to validate fixture locating schemes critical assembly interfaces and predict assembly process capability prior to tooling fabrication

• Ensure that assembly-level drawings and interface control documents clearly and unambiguously define the requirements necessary to guide tooling design and build process planning

Design for Assembly (DFA)

• Participate in design reviews (PDR CDR production readiness reviews) as the assembly tooling and build process subject matter expert providing early input on assembly sequences interface features and tolerances that drive tooling complexity operator ergonomics or build risk

• Review engineering drawings and 3D models for assembly feasibility providing formal DFA feedback to design engineering teams focused on accessibility clearance assembly sequence logic and interface features that drive tooling complexity or build risk

• Recommend design modifications feature simplifications or interface geometry changes that reduce assembly tooling cost improve build repeatability and reduce the risk of assembly errors

• Provide make/buy recommendations for assembly tooling fabrication based on internal capability lead time and cost considerations

Assembly Process Development

• Develop and maintain assembly process plans work instructions and traveler sequences that incorporate tooling and fixture usage at eachbuildstep ensuring clear repeatable operator guidance

• Collaborate with assembly technicians and production leads during newtoolingintroduction to validate ease of use ergonomics and build sequence alignment

• Apply Lean manufacturing principles to identify and eliminate sources of tooling-driven assembly variation build time and production downtime

• Collaborate cross-functionally with quality operations and design teams to resolve assembly tooling-related production issues and support continuous improvement initiatives

Tooling Lifecycle Management

• Establish and maintain an assembly tooling and fixture inventory system including configuration control calibration schedules preventive maintenance plans and end-of-life disposition criteria

• Develop and maintain tooling-related setup sheets usage instructions and traveler notes to ensure consistent and correct use of assembly fixtures across production shifts

• Drive continuous improvement of the assembly tooling portfolio by identifying opportunities to consolidate modernize or retire tooling based on production feedback and evolving build requirements

Minimum Qualifications

• Bachelors degree in Mechanical Engineering Manufacturing Engineering Industrial Engineering or related field

• 5 years of experience in manufacturing or tooling engineering in an aerospace defense or high-precision assembly environment

• Demonstrated hands-on experience leading the design and development of assembly fixturesbuildaids handling fixtures and installation tools for complex precision mechanical assemblies

• Demonstrated experience developing and executing assembly tooling validation plans including fit checks assembly runoff studies repeatability assessments and formal qualification documentation

• Proficiency in GD&T per ASME Y14.5; ability to independently interpret and apply geometric tolerancing schemes to assembly fixture design drawing review and build process planning

• Demonstrated experience performing tolerance stack-up analysis (1D/2D/3D) as applied to assembly interface validation and fixture locating scheme development

• Proficiency with 3D CAD tools (CREO/Pro-E SolidWorks or equivalent) for detailed fixture design and drawing package generation

• Familiarity with precision mechanical assembly processes including press fitting bearing installation fastener torque control adhesive bonding and subassembly integration as they relate to fixture and tooling requirements

• Strong analytical and communication skills; ability to present assembly tooling design and validation findings to cross-functional technical audiences

• Must be a U.S. citizen or national U.S. permanent resident or lawfully admitted into the U.S. as a refugee or granted asylum (as required by export control regulations)

Preferred Qualifications

• Demonstrated experience with the full lifecycle of assembly fixture design validation and production implementation for aerospace mechanism or motion control product manufacturing including build fixtures assembly aids and handling fixtures

• Experience designing and validating assembly tooling for high-volume or automated production lines including integration with robotic assembly systems automated fastening equipment or automated handling solutions

• Experience with Gauge R&R studies and measurement system analysis (MSA) as applied to assembly fixtures and in-process gauging

• Knowledge of tolerance stack-up analysis methods (1D/2D/3D) with demonstrated application to assembly fixture locating scheme validation and build process capability prediction

• Familiarity with aerospace quality management systems such as AS9100 and NADCAP including assembly tooling qualification and first article inspection (FAI) requirements per AS9102

• Experience with ERP/MES systems for tooling configuration control traveler management and nonconformance tracking including IFS SAP OracleDeltekCostpointSolumina(iBASEt)Apriso or equivalent platforms

• Familiarity with model-based definition (MBD) and ASME Y14.41 standards as applied to assembly tooling and fixture design packages

• Lean Six Sigma certification (Green Belt or higher)