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Tolerance Analysis Jobs (NOW HIRING)

Mechanical Design Engineer

San Jose, CA · On-site

$89K - $120K/yr

Perform 2D tolerance analysis for complex electro-mechanical assemblies . * Collaborate with manufacturing teams and suppliers to resolve design issues impacting field or production. * Exchange PCB ...

Senior Structural Analyst

San Jose, CA · On-site

$144K - $180K/yr

Perform stress analysis using Finite Element Methods for static, dynamic, fatigue, and/or damage tolerance to support program design, fabrication, testing, and/or structural integrity activities

Structural Analysis Engineer

Everett, WA · On-site

$105K - $185K/yr

The role involves performing thermo-mechanical analyses (including static, fatigue, damage tolerance, vibration, dynamics) using classical hand calculations, Finite Element Methods, and other ...

Conduct tolerance analysis and resolve GD&T interpretation issues. * Verify 3D models submitted to manufacturing for accuracy and compliance. * Collaborate with Engineering, Manufacturing, Quality ...

Conduct tolerance analysis , fit/function checks, and manufacturability reviews * Apply and interpret GD&T to resolve drawing issues * Validate 3D models prior to release to manufacturing

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Tolerance Analysis information

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$31.5K

$96.8K

$158K

How much do tolerance analysis jobs pay per year?

As of Aug 9, 2026, the average yearly pay for tolerance analysis in the United States is $96,807.00, according to ZipRecruiter salary data. Most workers in this role earn between $66,500.00 and $126,000.00 per year, depending on experience, location, and employer.

What are the key skills and qualifications needed to thrive in tolerance analysis, and why are they important?

To thrive in a Tolerance Analysis role, a strong background in mechanical engineering, manufacturing processes, and geometric dimensioning and tolerancing (GD&T) is essential, often supported by an engineering degree. Proficiency with CAD software, statistical analysis tools, and tolerance analysis applications like CETOL or Sigmetrix is commonly required. Attention to detail, problem-solving abilities, and clear communication are key soft skills that enhance effectiveness in this position. These skills ensure accurate analysis of part tolerances, reduce manufacturing errors, and foster successful collaboration with design and production teams.

What are the typical responsibilities of someone working in tolerance analysis?

Professionals in Tolerance Analysis are responsible for evaluating and defining the allowable variations in dimensions and assembly of mechanical parts to ensure products meet both quality and functional requirements. Their daily tasks often include reviewing engineering drawings, performing tolerance stack-ups, collaborating with design engineers to improve manufacturability, and documenting their analyses. Tolerance analysts frequently work as part of a multidisciplinary team, providing crucial input during the design and manufacturing stages to identify and mitigate potential assembly issues. This role is vital in industries such as automotive, aerospace, and consumer products, where ensuring reliable part fits and minimizing production risks are top priorities.

What is tolerance analysis?

A Tolerance Analysis job involves evaluating and controlling the dimensional variation of mechanical parts and assemblies to ensure proper fit, function, and manufacturability. Engineers performing tolerance analysis use statistical methods, CAD software, and geometric dimensioning and tolerancing (GD&T) principles to assess the impact of variations in production. This role helps optimize designs for cost efficiency, quality, and reliability while minimizing defects and assembly issues.

More about Tolerance Analysis jobs
What cities are hiring for Tolerance Analysis jobs? Cities with the most Tolerance Analysis job openings:
What states have the most Tolerance Analysis jobs? States with the most job openings for Tolerance Analysis jobs include:
Infographic showing various Tolerance Analysis job openings in the United States as of August 2026, with employment types broken down into 67% Full Time, and 33% Contract. Highlights an 89% In-person, and 11% Hybrid job distribution, with an average salary of $96,807 per year, or $46.5 per hour.

Lead, Aircraft Fatigue and Damage Tolerance Engineer

L3Harris Technologies

Waco, TX

Full-time

Posted 26 days ago


Job description

L3Harris is dedicated to recruiting and developing high-performing talent who are passionate about what they do. Our employees are unified in a shared dedication to our customers' mission and quest for professional growth. L3Harris provides an inclusive, engaging environment designed to empower employees and promote work-life success. Fundamental to our culture is an unwavering focus on values, dedication to our communities, and commitment to excellence in everything we do.

L3Harris is the Trusted Disruptor in defense tech. With customers' mission-critical needs always in mind, our employees deliver end-to-end technology solutions connecting the space, air, land, sea and cyber domains in the interest of national security.

Job Title: Lead, Aircraft Fatigue and Damage Tolerance Engineer
Job Code: 40917
Job Location: Waco, TX (Onsite)
Job Schedule: 9/80


Job Description:

L3Harris MMG Division is seeking an experienced Aircraft Fatigue and Damage Tolerance Engineer for our onsite aircraft modification facility located in Waco, TX. We offer competitive benefits and a generous relocation package for those who qualify.


The Aircraft Fatigue and Damage Tolerance Engineer will be responsible for performing structural fatigue and damage tolerance analysis of aircraft modifications, including design support, and preparation of technical documentation necessary to ensure airworthiness. This includes identification of critical load paths in primary aircraft structure resulting from applied and induced operational loads, as well as the determining the local stress concentrations, internal fastener load distributions, operational usage environments and design allowables. Additional responsibilities include development of tailored mission profiles and usage spectra for modified aircraft for use in calculation of service life.


Essential Functions:

  • Fatigue analysis of aircraft structures.
  • Crack growth analysis of aircraft structures.
  • Development of specific mission profiles and usage spectrum for modified aircraft.
  • Determination of inspection intervals for delivered aircraft.
  • Design support and drawing review.
  • Ability to generate free body diagrams, determine reaction forces, calculate internal load distributions, local stress concentrations, and operational usage environments.
  • Willingness and ability to travel as necessary.
  • Ability to obtain and maintain a Secret security clearance.
  • Willingness and ability to work any shift, weekends, and overtime as required.
  • Willingness to mentor less experienced engineers.
  • Effective and demonstrated leadership qualities.


Qualifications:

  • Bachelor's Degree in Mechanical Engineering, Aerospace Engineering, Civil Engineering and minimum 9 years of prior relevant experience. Graduate Degree (MSME, MSAE) and a minimum of 7 years of prior aircraft structural dynamics related experience. In lieu of a degree, minimum of 13 years of prior related experience.
  • Must be a US citizen.


Preferred Additional Skills:

  • Active security clearance.
  • Experience with predicting crack initiation lives and running industry-standard crack growth programs; e.g., AFGROW, NASGRO.
  • Working knowledge of one programming language.
  • Working knowledge of both military (Mil Standard) and civilian (14 CFRs) certification regulations and generating substantiation data to demonstrate compliance.
  • Working knowledge on how to develop the Airworthiness Limitations section of the Instructions for Continued Airworthiness for a structural modification.
  • Experience with standard Nondestructive Inspection (NDI) methods and corresponding crack growth detectable flaw sizes.
  • Experience with Dynamic Response Fatigue Analysis (High-Cycle Fatigue) due to high vibration environments and/or acoustic fatigue stresses.
  • CAD or analysis (FEA) tools exposure, and/or experience in mechanical design or analysis structures and mechanisms.
  • Familiarity with transducer instrumentation, data collection and or automation and software programming for numerical analysis.
  • Proficient in Microsoft Office, and have general computer knowledge.
  • Excellent verbal and written communication skills.

#LI-AS1

L3Harris Technologies is proud to be an Equal Opportunity Employer. L3Harris is committed to treating all employees and applicants for employment with respect and dignity and maintaining a workplace that is free from unlawful discrimination. All applicants will be considered for employment without regard to race, color, religion, age, national origin, ancestry, ethnicity, gender (including pregnancy, childbirth, breastfeeding or other related medical conditions), gender identity, gender expression, sexual orientation, marital status, veteran status, disability, genetic information, citizenship status, characteristic or membership in any other group protected by federal, state or local laws. L3Harris maintains a drug-free workplace and performs pre-employment substance abuse testing and background checks, where permitted by law.

Please be aware many of our positions require the ability to obtain a security clearance. Security clearances may only be granted to U.S. citizens. In addition, applicants who accept a conditional offer of employment may be subject to government security investigation(s) and must meet eligibility requirements for access to classified information.

By submitting your resume for this position, you understand and agree that L3Harris Technologies may share your resume, as well as any other related personal information or documentation you provide, with its subsidiaries and affiliated companies for the purpose of considering you for other available positions.

L3Harris Technologies is an E-Verify Employer. Please click here for the E-Verify Poster in English or Spanish. For information regarding your Right To Work, please click here for English or Spanish.

Employment Type: Full-Time