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The Mechanical Engineer / Tool & Die Designer is a dual-discipline role responsible for the end-to-end engineering of progressive dies used to produce micro-miniature metal stampings. Working primarily with thin-gauge Beryllium Copper (BeCu) and Phosphor Bronze (Phos Bronze) raw materials, this position applies advanced design, materials, and manufacturing knowledge to deliver precision tooling that meets exacting dimensional and functional tolerances. The role combines hands-on tool and die design with broader mechanical engineering responsibilities including new-product quoting, customer interface, production process proficiency, and engineering file management.

Essential Functions:

To accomplish this job successfully, an individual must be able to satisfactorily perform each stated essential function, with or without reasonable accommodation. Reasonable accommodation may be provided to help qualified individuals with disabilities perform the essential functions.

Key Responsibilities:

Progressive Die Design:

• Design and develop progressive stamping dies for the production of micro-miniature metal stampings from thin-gauge BeCu and Phosphor Bronze raw materials.

• Select appropriate die configurations, punch/die clearances, and progressive strip layouts accounting for BeCu and Phos Bronze material springback, work-hardening, and burr characteristics.

• Create detailed 2D and 3D engineering drawings and models using AutoCAD Inventor, AutoCAD Mechanical, and SolidWorks eDrawings Viewer.

• Develop strip layouts, die cross-sections, and detailed component drawings with GD&T callouts to print tolerances.

• Specify tooling materials, surface treatments, and heat-treat requirements for punch and die components.

• Utilize CAM software (Esprit) for EDM and CNC toolpath generation for die component fabrication.

Mechanical Engineering & Documentation:

• Perform engineering activities as required in support of product development, tooling design, and production operations.

• Maintain and organize engineering files in both hard-copy and electronic formats, ensuring revision control and document integrity.

• Collaborate with manufacturing, quality, and production personnel to resolve tooling and process issues.

• Prepare and distribute engineering documentation including drawings, procedures, and reports using MS Word, MS Excel, and Adobe Acrobat.

New Product Development & Customer Interface:

• Participate in the preparation of new product quotations, including feasibility assessment, die cost estimation, and cycle time analysis.

• Evaluate incoming customer RFQs for stampability, tolerancing, and material compatibility with BeCu and Phos Bronze alloys.

• Interface directly with customers on all aspects of design expectations, tolerance stack-up, and design-for-manufacturability (DFM) feedback.

Production Process Proficiency:

• Demonstrate proficiency in the production of reeled heat-treated (HT) and non-heat-treated stamped product (minimum one month hands-on OTJ training per process area).

• Demonstrate proficiency in the production of loose-piece heat-treated and non-heat-treated stamped product.

• Understand and support heat-treating, tumbling, winding, and reeling processes as applied to BeCu and Phos Bronze micro-stampings.

• Proficient in inspection processes including optical comparators, CMM, vision systems, and hand gauging for micro-miniature stamped parts.

Non-essential Responsibilities:

• Performs other duties as directed.

Position Qualifications and Competency Statements:

• Regard for Safety – Ability to follow safety rules and processes; keeps own safety and the safety of others in the forefront of every action, including in press-side and production floor environments.

• Technical Expertise – Deep knowledge of progressive die stamping fundamentals, thin-gauge BeCu and Phos Bronze material properties, GD&T, and precision manufacturing processes.

• Communication – Ability to effectively communicate technical information with customers, colleagues, and production personnel verbally and in writing.

• Problem Solving – Ability to diagnose and resolve complex tooling and process issues using analytical skills and hands-on experience.

• Accountability – Ability to accept responsibility and account for his/her actions and engineering decisions.

• Initiative – Ability to identify engineering and process improvement opportunities and drive them to completion without constant direction.

Skills and Abilities:

1. Associate’s or Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering Technology, or closely related field preferred; equivalent combination of technical education and documented experience will be considered.

2. Progressive Die Design Experience: Minimum 3–5 years of progressive die design experience in a precision metal stamping environment, with demonstrated experience in micro-miniature stampings at tight tolerances.

3. Material Knowledge: Experience working with thin-gauge BeCu and/or Phos Bronze strip materials strongly preferred.

4. CAD/CAM Proficiency: Proficient in AutoCAD Inventor, AutoCAD Mechanical, SolidWorks eDrawings Viewer, and CAM software (Esprit or equivalent).

5. Office Software: Proficient in MS Excel, MS Word, MS Outlook, and Adobe Acrobat for engineering documentation and communications.

6. Attention to Detail: Ability to interpret and create complex engineering drawings and work to tolerances in the thousandths-of-an-inch range.

7. Training Compliance: All skills verified through OTJ training with competence assessed via supervisor observation. An interpreter shall be used for all non-English-speaking employees.

Work Environment:

This position involves working in a precision manufacturing environment that includes both engineering office space and an active production floor. The employee must be aware of potential hazards including, but not limited to, working in close proximity to stamping presses and moving mechanical parts, EDM equipment, operating vehicles, exposure to metalworking fluids, high temperatures (heat-treating areas), and electrical current. PPE is required in designated production areas. It is important to maintain a high level of alertness and caution while performing tasks in this work environment.