Applications Engineering Manager – Wire EDM

Methods Machine Tools Inc • Sudbury, MA

11d • $139,108 - $180,841 • Onsite

About The Position

Methods Machine Tools was established in 1958 with three employees and a handful of refurbished machines. Since then, the company has become one of the largest privately owned machine tool importers in North America.

Job Summary: The Applications Engineering Manager – Wire EDM is a hands-on technical leader responsible for managing all Wire EDM applications engineering activities, with a primary focus on the FANUC Robocut product line. This role serves as the organization's subject matter expert on wire electrical discharge machining processes, providing pre-sales and post-sales technical support, driving turnkey solution development, and leading a team of applications engineers. The ideal candidate brings deep expertise in FANUC Robocut machines, EDM process optimization, and customer-facing technical consultation.

Requirements

• Deep, demonstrated knowledge of FANUC Robocut platforms, including CNC programming, power supply technology (SF3 / iPulse3), automatic wire feeding systems, and machine setup/optimization
• Expert understanding of wire EDM principles — discharge parameters, dielectric fluid management, wire tension control, surface finish optimization (to Ra 0.1 µm), taper cutting, and step/corner cutting techniques
• Proficiency in G & M code programming for Wire EDM, CAD/CAM software for EDM toolpath generation
• Thorough understanding of EDM behavior across conductive materials including hardened steels, carbides, titanium alloys, copper alloys, and superalloys
• Excellent verbal and written communication skills with the ability to translate complex technical concepts for customers, sales teams, and executive leadership
• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, or related technical discipline — or equivalent combination of education and 10+ years of progressive Wire EDM experience
• Minimum 8 years of hands-on Wire EDM applications experience, including at least 3 years in a supervisory or team lead capacity
• Strong leadership and team management abilities
• Excellent communication skills across all organizational levels

Nice To Haves

• Design experience and development of programmed applications highly preferred.
• Prior experience with Fanuc controls is highly preferred.
• Prior experience with CAM-I is highly preferred; experience with Mastercam or Esprit a plus
• Prior experience in a machine tool distributor or OEM applications engineering environment
• Familiarity with FANUC CNC ecosystem (controls, servos, robotics) beyond Wire EDM
• Experience with automation integration for unattended Wire EDM operations (pallet systems, robotic loading)
• Knowledge of complementary machining processes (sinker EDM, CNC milling, grinding) and how Wire EDM fits within a broader manufacturing workflow
• Lean manufacturing or Six Sigma certification is a plus

Responsibilities

• Serve as the company's foremost Wire EDM technical authority, with specific expertise in the FANUC Robocut a-C400, a-C600, and a-C800 platforms
• Develop and optimize cutting parameters, wire threading strategies, and machining processes across a range of materials (hardened tool steel, carbide, titanium, Inconel, etc.)
• Provide expert-level guidance on FANUC CNC controls, iHMI user interface, AWF3 automatic wire feeding, iPulse3 discharge control, Core Stitch slug retention, and AI-driven thermal compensation features
• Lead development of turnkey Wire EDM solutions including fixturing, programming, automation integration, and multi-axis (up to 7-axis) turn-and-burn applications
• Conduct test cuts, time studies, and machining demonstrations to validate process capabilities and support customer decision-making
• Partner with the sales organization to provide technical proposals, application feasibility assessments, and competitive positioning against Mitsubishi, Sodick, Makino, and other Wire EDM OEMs
• Conduct on-site and in-house customer training on Robocut machine operation, programming (G & M code), maintenance, and process optimization
• Serve as the technical escalation point for complex customer applications, troubleshooting, and process challenges
• Represent the company at trade shows, industry events, and technical seminars
• Develop and maintain a library of proven cut conditions, application notes, and technical documentation for internal and customer use
• Collaborate with FANUC engineering teams (domestic and Japan) on product feedback, beta testing, and new feature validation
• Track industry trends in Wire EDM technology, materials, and applications to identify new market opportunities across medical, aerospace, defense, energy, mold & die, and additive manufacturing sectors
• Contribute to continuous improvement initiatives and support ISO 9001 quality management objectives
• Recruit, develop, and manage a team of Wire EDM applications engineers, setting performance goals and conducting regular evaluations
• Establish training programs to ensure the team maintains current knowledge of FANUC Robocut technology, new product releases, and evolving EDM best practices
• Allocate engineering resources across pre-sales support, post-sales installation, customer training, and ongoing technical support activities
• Supervise geographically dispersed direct reports, ensuring operational efficiency and adherence to organizational policies.

Benefits

• Methods Machine is an Equal Opportunity/Affirmative Action employer. All qualified applicants will receive consideration for employment without regard to sex, gender identity, sexual orientation, race, color, religion, national origin, disability, protected Veteran status, age, or any other characteristic protected by law.

What This Job Offers

• Job Type: Full-time
• Career Level: Manager