Metrology Engineer

Job Purpose

The Metrology Engineer is Hyliion's technical authority on dimensional measurement across internal operations and the supply base. KARNO functionality depends on precision machined components and sub-assemblies held to micron-level form and finish, and this position sits within the Quality function as the interface between Design Engineering, the supply base, Manufacturing, and Quality. The role owns the measurement system end to end: the metrology lab and equipment roadmap, inspection programs and fixtures, the calibration and gage control system, and the measurement standards to which both supplier and internal inspection are held.

The position is accountable for the integrity of dimensional data wherever it is generated — at a supplier's machine, at receiving inspection, or in process on Hyliion's floor — and for ensuring that results from those sources agree within defined, documented tolerances. The balance between supplier-facing and internal work shifts with the maturity of the supply base and the product portfolio; both are permanent responsibilities of the role.

 

AI at Hyliion

At Hyliion, AI is core to how we work. We equip every team member with leading AI tools and count on you to use them — to move faster, solve harder problems, and help us realize the full potential of KARNO technology for the world.

 

Duties and Responsibilities

Supplier Metrology and Source Inspection

• Serve as Hyliion's technical lead for dimensional verification at key suppliers, including additive manufacturing partners, precision machining sources, and the magnetic assembly supply chain.
• Assess supplier measurement capability: equipment, environment, programs, fixtures, operator competency, and calibration integrity. Document findings and drive corrective action to closure.
• Design, specify, and validate inspection fixtures and holding methods for supplier-produced components; ensure fixture datum schemes replicate the drawing datum structure.
• Author, review, and approve supplier CMM and scanning programs, verifying that each program measures the characteristics as specified on the drawing.
• Lead First Article Inspection per AS9102 (or equivalent), including drawing ballooning, characteristic accountability, and disposition of nonconforming results.
• Conduct gage correlation and round-robin studies between Hyliion and supplier measurement systems; establish and maintain the accepted correlation offsets and their control.
• Qualify suppliers for documented, auditable self-certification and maintain periodic surveillance of those approvals.
• Support supplier PPAP-style qualification packages and the measurement evidence required for production part approval.

Design Engineering Interface — Measurability by Design

• Participate in design reviews as the voice of measurement: challenge datum schemes, tolerance callouts, and inaccessible features before drawings release.
• Perform and review GD&T application per ASME Y14.5; identify callouts that are ambiguous, unmeasurable, or measurable only at unreasonable cost.
• Support tolerance stack-up analysis on critical interfaces such as heater-to-chiller joints, bearing clearances, stator and translator concentricity, and pressure vessel sealing surfaces.
• Define Critical-to-Function and Key Characteristics with Design Engineering, and ensure every one has a documented, capable measurement method before production release.
• Advance Model-Based Definition and PMI adoption so that measurement intent flows from CAD to inspection program without manual reinterpretation.

Internal Metrology Capability

• Own the metrology equipment roadmap and capital justification across Hyliion sites: CMMs, structured-light and laser scanning, CT inspection for internal additive geometry, form and roundness measurement, surface finish, and hand gaging.
• Own the controlled metrology environment — thermal stability, isolation, and fixturing infrastructure — including the specification and commissioning of new capability.
• Develop and maintain internal inspection programs, work instructions, and inspection plans; train Quality Inspectors and Manufacturing personnel to execute them consistently.
• Own the calibration and gage control program: traceability to NIST, calibration intervals, recall system, out-of-tolerance investigation, and impact assessment on previously accepted product.
• Advance the organization from reactive inspection toward in-process measurement, statistical process control, and capability-based release.

Measurement Systems Analysis and Data Integrity

• Plan and execute Gage R&R, bias, linearity, and stability studies on all measurement systems used for product acceptance; drive systems that fail to meet criteria to remedy or replacement.
• Establish and maintain measurement uncertainty budgets for critical characteristics, and define acceptance decision rules that account for them.
• Own the dimensional data architecture — collection, storage, retrieval, and analysis — so that measurement results are traceable to serial number, revision, operator, equipment, and date.
• Apply SPC and capability analysis (Cp/Cpk, Pp/Ppk) to characteristics driving yield and warranty risk; translate measurement data into process improvement.

Manufacturing and Quality Support

• Support root cause investigation of dimensionally-driven nonconformances and field issues; provide the measurement evidence that separates a real defect from a measurement artifact.
• Contribute measurement capability inputs to PFMEA and Control Plans across product value streams.
• Support facility moves, new line bring-up, and capacity expansion with layout, equipment, and inspection method planning.
• Maintain dimensional traceability on serialized assemblies so that every unit has a complete, retrievable measurement history.

 

Additional duties and responsibilities as assigned, needed, or required for the business.

 

Qualifications

Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

Qualifications include:

• Education, Experience and Certifications
  • Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Technology, or a related technical discipline. Equivalent combination of technical training and directly relevant metrology experience will be considered.
  • Five or more years of hands-on dimensional metrology experience in a precision manufacturing environment — aerospace, defense, medical device, energy equipment, semiconductor capital equipment, or comparable.
  • Experience working directly with external suppliers, including on-site assessment, source inspection, and corrective action.
  • Experience in AS9100, ISO 9001, or NADCAP-governed quality systems is preferred.
  • Electric machine or precision electromechanical assembly experience (stator, rotor, magnet assembly, or air gap control) is preferred.
  • Experience supporting a product through the transition from prototype to serial production is preferred.
  • ASQ CQE, CCT, or CMI certification is preferred, as is NIST or A2LA metrology training.
• Skills and Abilities
  • Demonstrated expertise in GD&T per ASME Y14.5, including datum structure design and tolerance interpretation, not just callout reading.
  • Direct programming and operating experience with coordinate measuring machines (PC-DMIS, Calypso, Polyworks, Modus, or equivalent).
  • Working command of Measurement Systems Analysis — Gage R&R, bias, linearity, stability — and the ability to defend a measurement system to a customer or auditor.
  • Experience designing or specifying inspection fixtures and holding methods for complex geometry.
  • Practical knowledge of calibration systems and traceability requirements (ISO/IEC 17025, ANSI/NCSL Z540, or equivalent).
  • Ability and willingness to travel to supplier and Hyliion sites, primarily domestic with some international travel. Travel is typically 20-25% and runs higher during new supplier qualification or capability build-out.
  • Experience measuring additively manufactured components, including internal geometry verification by CT or industrial radiography, is preferred.
  • Structured-light or blue-light scanning experience (ATOS, Zeiss, Creaform) and point cloud to CAD comparison methods are preferred.
  • A form and surface metrology background (roundness, cylindricity, straightness, and profilometry on bearing-class surfaces) is preferred.
  • Familiarity with AS9102 First Article Inspection and AIAG PPAP submission requirements is preferred.
  • Model-Based Definition and PMI implementation experience is preferred.

 

Role Classification and Working Conditions

This is a salaried, exempt-level position. This position typically works in an office environment; and given the nature of our business is also exposed to operations/warehouses/production environments.

 

Physical/Other Requirements

• Split time across office, metrology lab, production floor, and supplier manufacturing environments.
• Required use of personal protective equipment in shop, laboratory, and supplier facility settings.
• Ability to lift and position fixtures and components up to 40 lbs.
• Extended periods of standing, and occasional work in confined or elevated positions during equipment setup and inspection.
• Ability to travel by air 25–50% of the time, primarily domestic with occasional international travel.
• Ability to travel internationally is an essential requirement of this position. Candidates must possess or be able to timely obtain and maintain valid documentation necessary for required international business travel.