Product Design and Development Engineer

Responsibilities:

Translating clinical prescriptions into detailed 3D device geometries using parametric CAD (Fusion 360 preferred) Managing the complete scan-to-print pipeline: structured-light scanning → mesh cleaning and rectification → CAD modelling → slicing → 3D printing Designing and iterating transtibial and transfemoral prosthetic socket geometries Developing and maintaining CornerStone's internal component library (prosthetic feet, pylon connectors, suspension components, cosmetic covers) Producing print-ready files with validated wall thickness, print orientation, and material-appropriate parameters Running iterative design reviews with clinicians and documenting design decisions and outcomes Contributing to product research — identifying device opportunities and authoring product briefs for leadership review Maintaining design documentation, technical drawings, and fabrication specifications to professional standards

Requirements:

Proficiency in parametric CAD software such as Autodesk Fusion 360, SolidWorks, or Rhinoceros 3D for 3D modelling and assemblies Experience with FDM and resin (SLA) 3D printing technologies Familiarity with slicer software such as Ultimaker Cura, PrusaSlicer, or ChiTuBox Strong mesh editing and repair skills using tools like Meshmixer and Blender Ability to prepare, manage, and convert 3D file formats (STL, STEP, OBJ, 3MF) Knowledge of technical drawing standards and basic GD&T (Geometric Dimensioning & Tolerancing) Ability to create and maintain accurate design documentation Experience with 3D scanning workflows, including structured-light scanning and photogrammetry Familiarity with generative design processes Knowledge of FEA (Finite Element Analysis) and structural simulation Understanding of topology optimisation techniques Working knowledge of composite and polymer materials used in manufacturing Familiarity with CAM workflows and CNC machining processes Experience with reverse engineering of physical components