Upholstery Development Engineer III

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Company:
Exemplis

Location:

Buena Park, CA, US, 90620 Cypress, CA, US, 90630

Work Designation:
Onsite

Salary Range
: $- $

We are seeking a hands-on and technically skilled Upholstery Development Engineer to support the end-to-end development of upholstered furniture products. As a key member of the Product Development team, you will lead in creating precise upholstery patterns and ensure a seamless transition from prototyping to production.

This role requires expertise in pattern development, upholstery construction, and close collaboration with cross-functional teams, including Product Engineering, Manufacturing, and Design. Strong experience in pattern making, upholstery fabrication, and Design for Manufacture (DFM) principles is essential for success.

This is a senior individual contributor role with technical ownership of pattern development standards and approvals.

• Establish pattern development best practices, workflows, & documentation to ensure consistency & efficiency
• Lead pattern development during product introduction to meet project goals, timelines, quality, ergonomics & aesthetic standards
• Review preliminary product designs for feasibility & suggest DFM optimizations
• Collaborate with Engineering & Design to refine foam shapes & densities for optimal fit, comfort, & manufacturability
• Review & approve patterns for structural integrity, ergonomic performance & manufacturability
• Use software to convert complex 3D surfaces into accurate 2D patterns and supporting sewing documentation
• Oversee prototype builds & resolve pattern issues related to foam, seams, or fabric tension
• Recommend product construction adjustments to improve fabric laydown & reduce variability
• Create & maintain living documents to communicate prototyping challenges & suggestions for improvement
• Serve as the key escalation point for pattern challenges, driving effective solutions & continuous improvement
• Use digital patterning, nesting, & grading tools integrated with automated cutting systems
• Identify cost & process optimization opportunities while maintaining product quality & aesthetics
• Manage BOMs, revisions, & technical documentation through PLM/PDM systems
• Create & maintain relevant upholstery & pattern making standards

Required Qualifications:

• 5+ years of upholstery pattern making & fabrication experience, including cut, molded, & over-molded foam applications
• Hands-on experience with foam, muslin, vinyl, & other upholstery prototyping materials
• Strong communication & collaboration skills with cross-functional & cross-cultural teams
• Proven ability to develop & refine complex foam assemblies for consistency & manufacturability
• Skilled in analyzing foam properties (compression, spring-back, adhesion) & applying insights to pattern design
• Proficiency in industrial sewing machines, upholstery tools, & prototyping equipment
• Advanced proficiency in at least one pattern making software such as Optitex, Gerber Accu Mark, Lectra, or Exact Flat
• Experienced in developing upholstered products from concept through production launch
• Ability to interpret sketches, CAD drawings, & 3D models into accurate production-ready patterns

Preferred Qualifications:

• Technical certification in Pattern making or equivalent
• Experience working with U.S.
  
  -based consumer product companies
• Familiarity with 3D patterning & visualization software (CLO, Browzwear, NX Master trim)
• Knowledge of North American manufacturing & rapid prototyping workflows, especially automotive trim
• Adaptable, detail-oriented, & proactive in problem solving
• Experience with cost reduction exercises
• Bilingual proficiency in English & Spanish (verbal & written)

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