Job Summary We are seeking a dynamic and detail-oriented Roll Form / Metal Forming Engineer to join our innovative manufacturing team. In this role, you will lead the design, development, and optimization of roll forming and metal forming processes to produce high-quality components efficiently. You will collaborate across engineering disciplines, utilize advanced CAD software, and implement continuous improvement strategies to enhance manufacturing performance. This position offers an exciting opportunity to apply your expertise in industrial automation, process engineering, and quality improvement programs to drive operational excellence in a fast-paced environment. Responsibilities Key Responsibilities Process & Tooling Engineering Design and develop roll forming flower patterns, progressive/transfer die layouts, and forming sequences using CAD/CAM software (e.g., SolidWorks, AutoForm, COPRA, Logopress). Perform forming simulations (springback, thinning, wrinkling, strain analysis) to validate designs before tool build. Specify tooling, die sets, punches, dies, rolls, and associated fixtures; work with toolmakers and outside vendors on build and modification. Lead die/roll tool tryouts, troubleshoot forming defects (springback, wrinkling, tearing, oil-canning, edge cracking), and implement corrective actions. Develop and maintain process parameters (tonnage, feed rates, roll station spacing, lubrication) and document standard work. New Product Introduction (NPI) Review new part designs for manufacturability (DFM/DFA) and provide feedback to product engineering on formability, tolerances, and material selection. Estimate tooling costs, lead times, and capital requirements for new programs and quotes. Manage tooling builds from concept through PPAP/production approval, including APQP documentation. Coordinate first-article inspection, capability studies (Cpk/Ppk), and customer sample submissions. Continuous Improvement & Cost Reduction Identify and lead projects to reduce scrap, cycle time, tool wear, and material usage. Apply Lean Manufacturing, Six Sigma, and Kaizen methodologies to forming operations. Drive root cause analysis (5-Why, fishbone, FMEA) for quality escapes and equipment downtime. Evaluate and implement automation, progressive die improvements, and press/line upgrades. Equipment & Maintenance Support Support maintenance and troubleshooting of stamping presses, roll form mills, uncoilers, straighteners, and in-line welding/punching stations. Partner with maintenance teams on preventive maintenance schedules for dies, rolls, and equipment. Evaluate and recommend capital equipment purchases (presses, roll form lines, transfer systems). Cross-Functional Collaboration Work closely with Quality, Production, Maintenance, Purchasing, and Product Engineering teams. Train and mentor production personnel, setup technicians, and die setters on process standards. Communicate technical issues and project status to management and customers as needed.

Maintain engineering documentation:

process sheets, work instructions, control plans, PFMEAs.

Core Competencies Technical Problem Solving:

Diagnoses root causes of forming defects quickly and develops durable corrective actions rather than temporary fixes.

Design & Simulation Proficiency:

Fluent in CAD tooling design and forming simulation software; translates part geometry into manufacturable tooling.

Project Management:

Manages multiple tooling/NPI projects simultaneously, meeting timelines and budgets.

Hands-On Orientation:

Comfortable spending significant time on the production floor during tryouts, launches, and troubleshooting — not purely a desk role.

Data-Driven Decision Making:

Uses SPC, capability studies, and simulation data to validate decisions rather than relying solely on experience or intuition.

Communication:

Explains technical concepts clearly to operators, toolmakers, customers, and leadership.

Continuous Improvement Mindset:

Actively seeks efficiency, quality, and cost improvements; champions Lean/Six Sigma tools.

Vendor & Supplier Management:

Effectively manages external toolrooms, material suppliers, and equipment vendors.

Adaptability:

Responds effectively to shifting priorities, urgent line-down issues, and evolving customer requirements. Qualifications Education Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or related field required. Equivalent combination of technical education and extensive hands-on stamping/forming experience will be considered in lieu of a degree. Experience 5-10+ years of progressive experience in metal stamping, roll forming, and/or metal forming process/tool engineering. Demonstrated experience with progressive die design and build, deep draw forming, and/or multi-stand roll form line design. Experience with high-volume production environments (automotive, appliance, construction products, HVAC, or similar). Proven track record leading tool tryouts, launches, and PPAP submissions. Experience with press equipment (mechanical/hydraulic/servo, 50-1000+ ton) and roll form mills. Technical Skills Proficiency in CAD software (SolidWorks, AutoCAD, or Catia) and forming simulation tools (AutoForm, Pam-Stamp, COPRA RF, or equivalent). Strong understanding of sheet metal properties, material behavior (springback, work hardening, anisotropy), and gauge/tolerance stack-up. Working knowledge of GD&T, blueprint reading, and dimensional inspection (CMM, laser scanning). Familiarity with APQP, PPAP, FMEA, and control plan documentation. Six Sigma Green/Black Belt certification a plus. Preferred Experience with progressive die stamping AND roll forming (both, not just one) is highly preferred. Experience with secondary operations integrated into forming lines (punching, welding, notching, in-line inspection). Familiarity with servo press technology and Industry 4.0 / data monitoring systems. Join us as we push the boundaries of metal forming technology! Bring your expertise in process optimization, automation integration, and engineering troubleshooting to help us deliver innovative solutions that elevate our manufacturing excellence. This role is perfect for passionate engineers eager to make a tangible impact through continuous improvement initiatives in a vibrant industrial setting.

Pay:

$85,000.00 - $100,000.00 per year

Benefits:

401(k) 401(k) matching Dental insurance Employee assistance program Flexible spending account Health insurance Life insurance Paid time off Retirement plan Vision insurance

Work Location:

In person