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