Advanced CNC Manufacturing Engineer

Carson Helicopters•Perkasie, PA

2d•$125,000 - $150,000•Onsite

About The Position

We are seeking an unusually capable CNC manufacturing professional to own the development of complex machining processes from engineering model through stable production. This is not a position limited to generating CAM toolpaths. The person in this role will determine how difficult components should actually be manufactured: datum strategy, operation sequence, workholding, fixture design, tooling, cutting methods, machine utilization, inspection, simulation, prove-out, and process documentation. The successful candidate may have come through either of two paths: An exceptional machinist-programmer who developed engineering-level process-design capability; or A manufacturing or applications engineer with extensive hands-on CNC programming and machine prove-out experience. A four-year engineering degree is not required. Demonstrated technical ownership of difficult machining projects is more important than educational pedigree.

Requirements

Advanced CNC programming experience involving genuinely complex components.
Hands-on experience with simultaneous 5-axis machining, multitasking machines, or mill-turn equipment.
Successful ownership of parts from initial planning through machine prove-out and production release.
Strong fixture, workholding, setup, and datum-strategy capability.
Practical understanding of cutting mechanics, rigidity, tool selection, speeds and feeds, tool life, and process stability.
Ability to interpret complex engineering drawings and GD&T.
Understanding of inspection planning, datum establishment, tolerance accumulation, and measurement limitations.
Experience using machine simulation or equivalent verification methods.
Ability to recognize when a CAM result is mathematically valid but physically unsafe or impractical.
Ability to diagnose problems across the complete system: model, drawing, CAM, postprocessor, machine, control, tooling, workholding, material, and inspection.
Independent research ability and willingness to consult technical manuals, supplier data, applications engineers, and subject-matter experts.
Clear written and verbal technical communication.
Sound judgment when working with expensive machines, high-value materials, and airworthiness-sensitive components.
Candidates will typically have substantial progressive machining experience, but demonstrated results matter more than a specific number of years.

Nice To Haves

Aerospace, rotorcraft, defense, medical, turbomachinery, motorsports, mold-and-die, or similarly demanding manufacturing.
Complex forgings, castings, thin-wall components, or difficult-to-machine alloys.
Dual-spindle, B-axis, multiturret, or multichannel mill-turn machines.
Custom fixture design using solid modeling and engineering calculations.
In-process probing and closed-loop process control.
Postprocessor development, modification, or technical coordination.
Machine acceptance testing or turnkey applications engineering.
First-article planning and aerospace-quality-system documentation.
Process-capability studies, control plans, and production stabilization.
Technical leadership or mentorship of other programmers and machinists.
Exact experience with every item above is preferred but not mandatory. Strong transferable process-development capability is more important than having used precisely the same software version or machine model.

Responsibilities

Review models, drawings, GD&T, material requirements, and production quantities for manufacturability.
Develop complete machining strategies for complex aerospace components.
Determine datum structures, operation sequences, setup quantities, and datum-transfer methods.
Design or direct the design of custom fixtures, jaws, pallets, mandrels, supports, and other workholding.
Evaluate workholding concepts for rigidity, accessibility, repeatability, distortion, clamping force, and tolerance accumulation.
Program complex 3-axis, 3+2, simultaneous 5-axis, turning, and mill-turn operations.
Develop processes for multichannel and multitasking machines, including spindle transfers and synchronized operations where applicable.
Select cutting tools, inserts, holders, extensions, coolant strategies, and machining parameters.
Consider machine kinematics, travel limits, singularities, tool reach, holder clearance, spindle limitations, and collision risk.
Use machine simulation and verification to validate programs before physical prove-out.
Work with postprocessor developers and equipment suppliers to identify and correct post, machine-definition, and control issues.
Develop probing, in-process verification, and final inspection strategies in coordination with Quality.
Plan for material movement, residual stress, thin-wall distortion, heat generation, tool deflection, and tolerance recovery.
Lead or directly participate in first-piece setup and machine prove-out.
Diagnose dimensional, finish, tool-life, chatter, collision-clearance, and process-stability problems.
Optimize cycle time without compromising safety, tool life, dimensional control, or process robustness.
Produce clear setup sheets, tool lists, fixture documentation, process plans, revision-controlled programs, and technical rationale.
Establish reusable CAM, tooling, fixture, simulation, and process-development standards.
Coordinate technical work with machine-tool, CAM, cutting-tool, workholding, probing, and metrology suppliers.
Mentor machinists and programmers and transfer sufficient knowledge for production personnel to run and maintain released processes.
Support equipment selection, capability analysis, estimating, and manufacturing planning for future work.