Senior Design Engineer

Kaspar Outdoors Job Description: Senior Design Engineer Opportunities: • Are you creative and innovative? • Are you an expert in CAD software and have a deep understanding of the manufacturing process? • Does working for a family-centric organization based in a small-town environment appeal to you? • Do the values of stewardship, versatility, and family resonate strongly with you? • Do you find the improvement of people’s lives through stewardship of God-given resources inspiring? Then, Kaspar Outdoors is for you! Primary Function: The Senior Technical Design Engineer leads mechanical design across new product development, cost reduction, and production support. This role blends expert CAD work with strong DFM/DFA principles to deliver scalable, manufacturable solutions in a lean environment. Position Responsibilities (including but not limited to): Design Ownership & Execution: • Lead mechanical design projects from concept through production release using SolidWorks. • Generate and manage detailed 3D models, assemblies, and fully toleranced 2D drawings. • Conduct tolerance stack-up analysis and apply GD&T to ensure fit/function in real-world manufacturing. • Select appropriate materials, coatings, and mechanical components for performance and manufacturability. • Manage engineering files and revisions using SolidWorks PDM. • Maintain engineering change control and revision tracking across product lines. Manufacturing & Cross-Functional Collaboration: • Work closely with CNC programmers, machinists, and assembly to ensure manufacturability and cost-efficiency. • Support tooling, fixture design, and prototype evaluation to bridge design and production. • Work closely with Manufacturing Engineering to drive root cause analysis and corrective action for design-related production issues. • Partner with purchasing and suppliers to resolve design constraints related to material or process capabilities. Continuous Improvement & Leadership: • Mentor design staff on best practices, GD&T, DFM/DFA, and design workflows. • Propose and implement improvements to design workflows, drawing standards, and product documentation. • Lead design reviews and support lean initiatives (e.g., Kaizen events, standard work definition). Skills: Technical Skills: • Expert in SolidWorks, including parametric modeling, configurations and assemblies. • Proficient with SolidWorks PDM for file management and design revision control. • Understanding of GD&T, Knowledge of drawing standards, and tolerance analysis. • Strong DFM/DFA skills and understanding of machining, metal fabrication with knowledge of composites. • Familiar with FEA, design validation, and physical testing methodologies. • Strong grasp of materials, coatings, and finishes, especially for stainless steel, aluminum, and composites. Soft Skills & Attributes: • Strong technical communication skills, both written and verbal. • Highly organized with a detail-oriented mindset. • Proven ability to take initiative and drive projects with minimal oversight. • Comfortable operating in a fast-paced, cross-functional environment. Qualifications: Required: • Bachelor’s Degree in Mechanical Engineering or related field, or equivalent hands-on experience. • 5+ years of mechanical design experience in a production-focused environment. • Mastery of SolidWorks and SolidWorks PDM. • Demonstrated ability to take designs from concept to production with minimal revision cycles. • Strong problem-solving mindset with experience in root cause analysis and continuous improvement. Preferred: • Background in firearms, defense, or precision manufacturing. • Familiarity with ERP/MRP systems and engineering document control practices. • Experience leading or mentoring junior engineers. Physical Requirements: • Extended periods of sitting and/or walking (33% - 75% of time) • Stooping, bending, twisting, leaning (10% - 25% of time) • Lifting of up to 25 lbs. occasionally (0% - 33% of time) Work Environment: • Frequent work in a manufacturing environment where the use of proper protective equipment (PPE) such as eye protection, hearing protection and safety shoes is mandatory Apply Job!