Technical Pattern Developer Sr

Position Summary:

We are seeking a hands-on and technically skilled Senior Technical Pattern Developer 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 patternmaking, 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.

Responsibilities and Essential Functions:

• 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 


• Interpret design/CAD into production-ready patterns


• 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 & patternmaking standards

Qualifications, Skills and Education:

Required Qualifications: 

• 5+ years of upholstery patternmaking & 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 patternmaking software such as Optitex, Gerber AccuMark, Lectra, or ExactFlat 


• 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 Patternmaking or equivalent 


• Experience working with U.S.-based consumer product companies


• Familiarity with 3D patterning & visualization software (CLO, Browzwear, NX Mastertrim)


• 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) 

Physical Demands 

• Ability to stand for extended periods & handle upholstery materials, leather, & tools