Repair & Development Design Engineer in Tempe, Arizona at SETNIX LLC

Setnix, a Setna iO company, is an FAA- and EASA-certified repair station delivering high-quality maintenance, repair, and overhaul solutions for the aviation and aerospace industry. Based in Tempe, Arizona, Setnix specializes in APU and Main Engine teardown, inspection, testing, repair, overhaul, and certification of high-demand rotables and aircraft components.

The Repair & Development Design Engineer is responsible for developing engineering concepts, repair solutions, tooling, fixtures, and component designs that support aircraft and engine component repair operations. This position works from initial concept through design and implementation to develop practical engineering solutions for new and existing repair processes.

The Design Engineer works closely with Engineering, Quality, Production, Machining, and Inspection personnel to develop repair methods, tooling, and design solutions that meet applicable technical, quality, safety, and regulatory requirements.

Job Responsibilities

• Develop engineering concepts and design solutions for the repair and restoration of aircraft, APU, and Main Engine components.
• Design tools, fixtures, gauges, and other equipment required to support repair, machining, inspection, assembly, and production processes.
• Develop concepts for new repair capabilities and improvements to existing repair processes.
• Create and modify engineering drawings, models, layouts, and technical documentation using CAD and other engineering design software.
• Develop detailed designs from initial concepts through final drawings and implementation.
• Evaluate damaged or worn components and assist in developing practical repair solutions.
• Support the development of repair procedures, work instructions, tooling requirements, and technical documentation.
• Determine appropriate dimensions, tolerances, materials, finishes, and design requirements for tooling and repair applications.
• Apply geometric dimensioning and tolerancing (GD&T) principles to engineering drawings and designs.
• Perform engineering calculations and dimensional evaluations as required to support designs and repair concepts.
• Review OEM manuals, component maintenance manuals, engineering drawings, technical specifications, and other approved technical data.
• Work closely with Machining, Production, Inspection, and Quality personnel to ensure designs can be effectively manufactured and implemented.
• Provide technical support during prototype development, testing, machining, and implementation of new tooling and repair processes.
• Evaluate prototypes and completed tooling to verify functionality, fit, accuracy, and performance.
• Identify opportunities to improve existing tooling, repair methods, processes, efficiency, and component quality.
• Troubleshoot design, tooling, dimensional, and manufacturing issues and recommend appropriate engineering solutions.
• Maintain accurate engineering drawings, design revisions, calculations,specifications, and project documentation.
• Support research and development projects related to expanding Setnix repair capabilities.
• Ensure engineering designs and repair-development activities comply with applicable company procedures, quality requirements, and aviation industry standards.
• Perform other engineering and repair-development duties as assigned.

Qualifications

• Bachelor’s degree in mechanical engineering, Aerospace Engineering, Manufacturing Engineering, or a related engineering discipline preferred.
• Previous experience in mechanical design, manufacturing engineering, repair development, aerospace engineering, or a related technical field preferred.
• Experience designing tooling, fixtures, gauges, mechanical components, or manufacturing equipment preferred.
• Experience within aviation, aerospace, MRO, turbine engine, APU, or precision manufacturing environments preferred.
• Proficiency with CAD software and the ability to create and modify detailed engineering drawings and 3D models.
• Strong understanding of mechanical design principles, manufacturing processes, materials, tolerances, and engineering fundamentals.
• Knowledge of machining processes, including turning, milling, grinding, and other precision manufacturing operations.
• Ability to read and interpret engineering drawings, blueprints, technical specifications, manuals, and repair documentation.
• Working knowledge of GD&T, dimensional tolerances, datums, fits, and engineering drawing standards.
• Ability to take a project from initial concept through design, prototype development, testing, and implementation.
• Strong analytical, troubleshooting, and problem-solving abilities.
• Strong attention to detail and ability to accurately document engineering work.
• Ability to communicate technical concepts effectively with Engineering, Quality, Production, Inspection, and Machining personnel.
• Ability to manage multiple engineering and development projects in a fast-paced environment.
• Ability to follow established safety, quality, engineering, and regulatory procedures.

Physical Requirements

• Ability to lift and carry up to 30 lbs.
• Ability to sit or stand for extended periods during the workday.
• Ability to frequently walk between office, engineering, and production/shop environments.
• Ability to bend, reach, and handle tools, components, fixtures, and measuring equipment as required.
• Ability to use computers and engineering/design software for extended periods.
• Ability to safely work around manufacturing, machining, and aerospace repair equipment.
• Ability to wear required personal protective equipment (PPE) while working in designated production areas.
• Ability to perform job duties safely in both office and shop/manufacturing environments.

Why You’ll Love It Here

• A collaborative, people-first culture where your voice and expertise truly matter.
• Competitive compensation, comprehensive health benefits, and a 401(k).
• Access to a strong network, best-in-class tools, and ongoing professional development.
• Onsite gym.