Entry Level Physical Design Engineer Jobs in Houston, TX

More than a decade ago, Ledge introduced America to the first-in pool chaise and modern design forward furniture for a more compelling outdoor living experience. Today the award-winning brand is recognized as the in-pool and poolside leader, adopted by discerning homeowners and five-star resort and residential properties around the world.

Our continued success is very much a consequence of our team members, the Ledge culture of collaboration and innovation, and our unwavering belief in the importance of design distinction in everything we do. If you are committed to your growth, collaborative both in spirit and action, and seeking to join a high performing team that both works hard and plays hard, we encourage you to apply.

Job Overview:

At Ledge, we believe outdoor spaces are not just extensions of the home—they're living works of art. As pioneers in the premium in-pool and poolside product design space, our mission is simple yet powerful: to help our customers manifest their identity by elevating their approach to outdoor living.

We are seeking an experienced and dynamic Design Engineer with deep expertise in plastics and fabrication to join our Product Development team. In this role, you will bridge the gap between creative design and flawless execution for both outsourced and in-house production. You will be responsible for transforming concepts into production-ready 3D CAD models, collaborating with external vendors on molded parts (injection molding, rotomolding, and blow molding), and directly owning the design and prototyping for our in-house manufacturing line. The candidate will apply Design for Manufacturing (DFM) and Design for Assembly (DFA) methodologies to ensure premium quality, structural integrity, and efficient production.

Key Responsibilities:

1. Advanced 3D Modeling: Create, edit, and update complex 3D parametric models and engineering drawings for new and existing products using SolidWorks and Rhino.
2. In-House CNC & Sheet Design: Design parts and products specifically optimized to be cut from High-Density Polyethylene (HDPE) sheets, maximizing material yield and minimizing waste.
3. DFM & DFA Optimization: Apply rigorous Design for Manufacturing (DFM) and Design for Assembly (DFA) principles to all products. Ensure in-house items feature intuitive, efficient, and robust assembly methods.
4. Vendor Collaboration: Act as the primary technical point of contact with external tooling and molding vendors. Review tool drawings and make necessary design adjustments (draft angles, wall thickness, parting lines) to achieve a flawless finished goods.
5. Prototyping & CNC Programming: Program toolpaths for CNC machines using CAMWorks. Hands-on fabrication, cutting, and assembly of physical prototypes to validate design concepts.
6. Testing & Documentation: Perform physical testing on prototypes, track engineering changes, and create highly accurate Bills of Materials (BOMs) and consumer instruction manuals.
7. Continuous Improvement: Identify process or design deficiencies in both molded and sheet-routed products, developing engineering solutions to improve quality and throughput.

What Success Looks Like:

Success in this role is measured by the ability to transform innovative concepts into manufacturable, high-quality products that reflect Ledge's commitment to design excellence. The Design Engineer will:

• Design production-ready products that balance aesthetics, functionality, manufacturability, durability, and cost while maintaining Ledge's premium brand standards.
• Deliver accurate 3D models, engineering drawings, Bills of Materials, and technical documentation that enable efficient production and minimize engineering changes.
• Partner effectively with Product Development, Manufacturing, and external vendors to accelerate product launches, resolve manufacturing challenges, and continuously improve product quality.
• Apply Design for Manufacturing (DFM) and Design for Assembly (DFA) principles to reduce complexity, improve assembly efficiency, and optimize production processes for both in-house and outsourced manufacturing.
• Develop and validate prototypes through hands-on testing, using findings to refine designs and ensure products meet performance, quality, and customer expectations.
• Foster a mindset of continuous improvement by identifying opportunities to enhance product performance, manufacturing efficiency, material utilization, and overall customer experience.

• Education: Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, or a closely related field preferred (Associate degree with extensive relevant experience considered).
• Plastics & Molding Expertise: Proven experience designing parts for Injection Molding, Rotomolding, and Blow Molding, with a strong understanding of tooling constraints.
• Sheet Fabrication & Assembly: Experience designing products utilizing CNC routing and mechanical assembly methods.
• CAD/CAM Proficiency: Advanced proficiency in 3D Parametric Modeling and surface modeling (SolidWorks required) . Strong working knowledge of CAM software (CAMWorks preferred) for generating CNC toolpaths.
• Vendor & Project Management: Experience collaborating with external toolmakers and internal production teams to troubleshoot manufacturing challenges and refine designs.
• Hands-On Skills: Proficiency with CNC machinery, basic hand tools, and small power tools for prototype fabrication.
• Soft Skills: Effective time management and logical decision-making ability. Excellent communication, leadership and interpersonal skills.
• Schedule: Monday – Friday, 8:00 AM to 5:00 PM.
• Must be able to lift 75+lbs on a regular basis (with support).
• Moving, bending, kneeling, and handling is required.

At Ledge, we value diversity and inclusion and are committed to providing equal employment opportunities to all individuals. We offer a competitive salary, benefits package, and the opportunity to work with a dynamic team in a positive and supportive work environment.