Design Engineer – Metal Fabrication

Location: Gastonia, North Carolina

Job Type: Full-time

Company: IFAB

About IFAB

At IFAB, we are a leading provider of custom metal fabrication services, dedicated to delivering precision engineering and superior manufacturing solutions. We take pride in building high-quality, innovative metal products for diverse industrial applications.

Job Overview

We are seeking a skilled, detail-oriented, and motivated Design Engineer to join our engineering team in Gastonia, NC. In this role, you will design and develop high-performance metal components, structural assemblies, and sheet metal products tailored to customer specifications and manufacturing capacities.

You will work in close collaboration with our shop floor production team to ensure every design is feasible, cost-effective, durable, and strictly compliant with quality standards.

Key Responsibilities

Product Design & Development

• Design, 3D model, and prototype custom metal products using CAD software (SolidWorks, AutoCAD).

• Develop detailed engineering drawings, complete with technical specifications, tolerances, and material requirements.

• Create accurate 3D models and simulations to assess functional performance, manufacturability, and cost-efficiency.

Cross-Functional Collaboration

• Partner closely with manufacturing and production teams to ensure design practicality and seamless execution on the shop floor.

• Liaise directly with customers, suppliers, and internal stakeholders to gather engineering requirements and clarify design specifications.

• Provide real-time engineering support to shop floor operators during fabrication, troubleshooting design challenges or applying required modifications.

Materials & Manufacturing Process Selection

• Select and recommend optimal materials and fabrication methods (welding, cutting, stamping, bending, CNC machining) based on structural requirements and budget.

• Collaborate with the broader engineering team to refine manufacturing workflows, minimizing unit costs while maintaining superior product quality.

Design Validation & Testing

• Conduct formal design reviews, simulations, and empirical testing to validate structural integrity, performance, and functionality.

• Identify and address design limitations or flaws, making adjustments to maximize ease of manufacturing and cost savings.

Documentation & Technical Reporting

• Prepare, organize, and maintain comprehensive technical documentation, including CAD design files, engineering drawings, and revision histories.

• Deliver regular progress reports and project status updates to executive leadership and project managers.

Continuous Improvement & Innovation

• Identify and implement engineering enhancements to optimize production efficiency, reduce raw material scrap, and extend product lifespan.

• Stay current on emerging metal fabrication technologies, tooling, and materials to integrate innovative solutions into future product designs.

Candidate Qualifications & Requirements

Required Qualifications:

• Education: Bachelor’s degree in Mechanical Engineering, Industrial Engineering, or a related engineering field.

• Experience: 3 to 5 years of hands-on design engineering experience within a metal fabrication or manufacturing environment.

• CAD Expertise: Proven, high-level proficiency in SolidWorks and AutoCAD (or equivalent 3D CAD platforms).

• Metal Fabrication Knowledge: Deep understanding of sheet metal parts, stamping, machining, bending, cutting, and welding processes, as well as tooling and fixture design.

• Technical Standards: Strong mastery of blueprint reading, interpreting technical specifications, quality standards, and GD&T (Geometric Dimensioning & Tolerancing) notes.

• Product Lifecycle: Direct experience managing the complete product design lifecycle—from initial concept through prototyping, shop floor testing, and full production.

• Engineering Principles: Solid foundation in structural engineering concepts and manufacturing constraints.

• Soft Skills: Exceptional analytical and problem-solving abilities, paired with strong verbal/written communication and teamwork skills.

Preferred Qualifications:

• Experience with Finite Element Analysis (FEA) for stress testing, load simulation, and design validation.

• Familiarity with ERP (Enterprise Resource Planning) and PLM (Product Lifecycle Management) systems.

• Practical working knowledge of industry welding codes and standards (e.g., AWS, ASME).

Working Conditions & Environment

• Dynamic work environment split between office space and the manufacturing floor in Gastonia, NC.

• Occasional site visits and domestic travel may be required.

• Flexible working schedule based on active project deadlines and operational needs.