Technical Pattern Developer Sr

Overview In this senior, hands-on role you will own pattern development standards for upholstered furniture, guiding patterns from prototyping through production. You will collaborate with Product Engineering, Manufacturing, and Design to ensure ergonomic, aesthetic, and manufacturable outcomes. You’ll drive best practices, optimize DFМ, and lead pattern-related decisions for high-quality, scalable production. This position offers meaningful impact on product construction and tooling in a fast-paced, cross-functional environment. Compensation / BenefitsCompetitive salaryEmployee discounts across product linesHit our Numbers Lunch ResponsibilitiesEstablish pattern development best practices, workflows, and documentation for consistency and efficiencyLead pattern development during product introduction to meet goals for quality, ergonomics, and aestheticsReview designs for feasibility and suggest DFМ optimizationsCollaborate with Engineering and Design to refine foam shapes and densities for fit, comfort, and manufacturabilityReview and approve patterns for structural integrity and manufacturabilityTranslate design/CAD into production-ready patternsUse software to convert 3D surfaces to 2D patterns with sewing documentationOversee prototype builds and resolve issues related to foam, seams, or fabric tensionSuggest construction adjustments to improve fabric laydown and reduce variabilityCreate and maintain living documents communicating prototyping challenges and improvementsServe as escalation point for pattern challenges and drive continuous improvementUtilize digital patterning, nesting, and grading tools with automated cutting systemsIdentify cost and process optimization opportunities while preserving quality and aestheticsManage BOMs, revisions, and technical documentation through PLM/PDM systemsCreate and maintain upholstery and patternmaking standards Key requirements5+ years of upholstery patternmaking and fabrication experience including foam applicationsHands-on experience with foam, muslin, vinyl, and other prototyping materialsStrong communication and collaboration skills across cross-functional teamsAbility to develop and refine complex foam assemblies for consistency and manufacturabilityAnalyze foam properties (compression, spring-back, adhesion) to inform pattern designProficiency with industrial sewing machines, upholstery tools, and prototyping equipmentAdvanced proficiency in patternmaking software (Optitex, Gerber AccuMark, Lectra, ExactFlat)Experience taking upholstered products from concept to production launchAbility to interpret sketches, CAD drawings, and 3D models into production-ready patternsclear communicationcross-functional collaborationproblem solvingOptitexGerber AccuMarkLectra