Product Design & Development Engineer

About the role

Cornerstone Prosthetics and Orthotics Ltd is looking for a Product Design and Development Engineer to convert clinical prescriptions into custom 3D‑printed prosthetic devices. The role blends parametric CAD modelling, structured‑light scanning, and additive manufacturing to create high‑quality transtibial and transfemoral socket geometries.

Key responsibilities

• Translate clinical prescriptions into detailed 3D device geometries using parametric CAD (Fusion 360 preferred).
• Manage the full scan‑to‑print workflow: structured‑light scanning, mesh cleaning, CAD modelling, slicing, and 3D printing.
• Design and iterate transtibial and transfemoral prosthetic socket geometries.
• Develop and maintain Cornerstone’s internal component library (prosthetic feet, pylons, suspension components, cosmetic covers).
• Produce print‑ready files with validated wall thickness, orientation, and material parameters.
• Conduct iterative design reviews with clinicians and document decisions and outcomes.
• Identify new device opportunities, author product briefs, and support research initiatives.
• Maintain design documentation, technical drawings, and fabrication specifications to professional standards.

Required profile

• Mid‑level experience (minimum 48 months) in product design or medical device development.
• Proven ability to work closely with clinicians and document design processes.
• Strong understanding of technical drawing standards and basic GD&T.
• Experience handling design documentation and revision control.

Required skills

• Parametric CAD software: Autodesk Fusion 360, SolidWorks, Rhinoceros 3D.
• FDM and SLA 3D printing technologies.
• Slicer software: Ultimaker Cura, PrusaSlicer, ChiTuBox.
• Mesh editing and repair tools: Meshmixer, Blender.
• 3D file format conversion (STL, STEP, OBJ, 3MF).
• Structured‑light scanning and photogrammetry workflows.
• Generative design processes.
• Finite Element Analysis (FEA) and structural simulation.
• Topology optimisation techniques.
• Knowledge of composite and polymer materials for manufacturing.
• CAM workflows and CNC machining basics.
• Reverse engineering of physical components.