Senior Design Engineer – DeKalb IL

Forge Resources Group consists of six manufacturing facilities located throughout the Midwest, specializing in closed die forging, metal forming, & fabrication. We are looking for a Senior Design Engineer to work at our DeKalb, IL Corporate Office.

FRG Vision Statement

To continually offer our people development opportunities within a stable and safe workplace. We will continuously improve our capabilities to meet the on-going expectations of our customers. Our success affords us a significant marketplace position in which to continue our sustainable growth as a premier solutions provider.

Job Purpose:

The primary focus of the Senior Design Engineer will relate to new product development & implementation. This role will be responsible for working independently across all levels of the company and managing multiple different projects simultaneously. This individual will have previous experience in a fast-paced forging or metal working environment. Industry background & expertise are required to create a positive, immediate impact.

Duties and Responsibilities:

  • Develop & lead new designs for several new applications each year. Successfully manage implementation at several different work centers and facilities.
  • Collaborate with customers regarding new product design to develop manufacturing requirements. Identify manufacturing constraints upfront and provide solutions based on expertise.
  • Adapt & improve existing processes & tooling into new, different work centers to improve quality, efficiency, throughput, etc.
  • Generate clear and precise technical documentation, transforming complex technical data into comprehensible content for various organizational levels.
  • Collaborate directly with manufacturing and research teams to establish and clarify specifications focused on performance, cost-effectiveness, and efficiency.
  • Utilize advanced computer-assisted engineering and design tools to create tooling and execute detailed forging simulations.
  • Communicate effectively across all levels within the organization, maintaining clarity and persuasiveness in both favorable and challenging situations.
  • Troubleshoot & identify manufacturing issues with production and quality personnel in a manufacturing environment with minimal preparation.
  • Implement process improvements on existing products and processes.
  • Work in a team role within a project team to enhance capability & capacity through equipment installations, process improvements, automation, etc.


  • Bachelor’s Degree in Mechanical Engineering
  • Expertise with 2D and 3D CAD software (SolidWorks preferred)
  • Proficiency in using forging or metal forming industry simulation software.
  • 3 years of tool & die design experience within a forging or metal forming industry.
  • 5 years of experience in forging or metal forming industries.
  • Profound knowledge of forging processes & equipment, and considerable experience with highly complex forgings
  • Expertise in at least one of the following processes: Hammer Forging, Press Forging, Upset Forging, Metal Forming, CNC Machining
  • Proficiency interpreting and creating technical drawings per ASME Y14.5-2018.
  • Experience reading, interpreting, and communicating technical specifications.
  • Strong understanding of common machining methods (milling, turning, EDM, welding, etc.)
  • Strong communications skills, specifically in technical writing
  • Experience working in a fast-paced, job shop, manufacturing environment.

Working Conditions:

  • Typical Hours: 8:00 AM – 5:00 PM, M-F
  • Location: FRG Corporate Office, 1801 Pleasant St., DeKalb, Il 60115
  • Subject to exposure in manufacturing environments
  • Lifting and manipulating parts weighing up to 40 lbs.
  • Travel Required: typically, 1-2 times per week, within 1-1.5 hours of DeKalb, Il

Candidates must pass a pre-employment Drug Screen, physical and detailed background check. The Drug Screen includes screening for all drugs that are illegal under federal law, regardless of state or local ordinances.