Composites Machining Manufacturing Engineer II

Firefly Aerospace•Firefly - Briggs, TX

About The Position

Firefly Aerospace is seeking a Composite Machining Manufacturing Engineer to join its Structures Department and develop and scale manufacturing processes for advanced composite aerospace structures. The engineer will develop, implement, and continually improve machining processes for carbon-fiber composite components, taking processes from initial development through full-rate production. The role includes developing tooling and workholding solutions, supporting CNC and robotic machining programming, and providing technical expertise to ensure parts meet quality, cost, and schedule requirements. The manufacturing environment uses Mastercam for CNC programming, Mastercam and Robotmaster for robotic machining programming, KUKA industrial robotic machining cells, and conventional multi-axis CNC equipment. The position requires aerospace manufacturing and composite machining knowledge, practical problem-solving skills, and the ability to become an expert on complex hardware and manufacturing systems. The engineer will serve as a subject-matter expert and primary point of contact for assigned composite machining operations and hardware, with hands-on production-floor support and cross-functional collaboration.

Requirements

Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Aerospace Engineering, or a related engineering field.
Significant experience in aerospace manufacturing with demonstrated experience in composite machining, CNC manufacturing, robotic machining, or advanced structures manufacturing.
Strong understanding of carbon-fiber composite materials and the challenges of machining composite structures.
Hands-on experience developing or supporting CNC routing, trimming, drilling, milling, or other machining processes.
Strong understanding of CNC machining principles, cutting tools, feeds and speeds, workholding, fixturing, machine setup, and manufacturing process development.
Experience interpreting engineering drawings, CAD models, tolerances, and GD&T.
Strong technical aptitude and ability to quickly become an expert on complex aerospace hardware and manufacturing equipment.
Proficiency with CAD/CAM software for reviewing hardware and developing manufacturing processes, tooling, and fixturing.
Demonstrated ability to troubleshoot complex manufacturing issues using structured problem-solving and root-cause-analysis techniques.
Experience supporting production manufacturing operations and working directly with machinists, technicians, programmers, and production personnel.
Excellent communication skills and ability to collaborate with cross-functional engineering and manufacturing teams.
Demonstrated record of driving process improvements and measurable improvements in quality, cost, throughput, or schedule.
High initiative and self-motivation, with ability to thrive in a dynamic, fast-paced aerospace manufacturing environment.
Excellent analytical and problem-solving abilities.

Nice To Haves

5 or more years of experience in aerospace manufacturing, machining, manufacturing engineering, or a related engineering environment.
Experience machining CFRP, fiberglass, honeycomb sandwich panels, Rohacell or other foam-core structures, bonded composite assemblies, and large composite structures.
Experience programming or supporting 3-axis and 5-axis CNC routers or machining centers.
Hands-on Mastercam experience for multi-axis CNC machining and toolpath development.
Robotmaster experience for offline robot programming, simulation, collision detection, reach analysis, and robot code generation.
Experience programming, proving out, or supporting KUKA industrial robotic machining systems.
Experience developing machining workflows using Mastercam, Robotmaster, and KUKA robotic machining cells.
Experience with robotic trimming, drilling, routing, and milling of large aerospace composite structures.
Understanding of industrial robot kinematics and differences between conventional CNC and robotic machining, including stiffness, accuracy, repeatability, reach, singularities, compliance, and dynamic response.
Experience integrating KUKA robots with external machining spindles, tooling systems, workholding systems, and production equipment.
Experience establishing and validating Tool Center Points (TCP), work coordinate systems, fixture coordinate systems, robot calibration, and part localization for robotic machining.
Experience troubleshooting robotic machining programs involving tool orientation, reach, singularities, collisions, motion transitions, and machining-induced deflection.
Experience with CNC probing and automated part setup systems, including Renishaw or similar technologies.
Experience developing vacuum fixtures, composite machining fixtures, drill fixtures, and large-part workholding systems.
Experience with machine-tool and robotic-cell accuracy, calibration, volumetric compensation, and process capability studies.
Experience with automated tool setters, cutter-life monitoring, and machining process automation.
Experience with metrology and inspection systems such as CMMs, laser trackers, portable measurement arms, or 3D inspection software.
Understanding of machine-code and robotic programming concepts, including G-code, cutter compensation, work coordinate systems, tool offsets, probing cycles, TCPs, and multi-axis machining.
Experience developing machining processes for large aerospace structures and tight-tolerance composite components.
Experience implementing CNC equipment or robotic manufacturing cells from requirements development through production qualification.
Experience with Lean Manufacturing, Six Sigma, PFMEA, control plans, SPC, and structured root-cause analysis.
Six Sigma or Lean Manufacturing certification.
Master's degree in Mechanical, Manufacturing, or Aerospace Engineering.

Responsibilities

Lead development and implementation of machining processes for aerospace composite components, including trimming, routing, drilling, milling, profiling, countersinking, and other secondary operations.
Develop and optimize machining strategies for CFRP, sandwich structures, honeycomb and foam cores, bonded assemblies, and other composite configurations.
Develop CNC processes covering cutter selection, feeds and speeds, toolpaths, workholding, datums, probing, inspection, and process controls.
Develop, review, simulate, prove out, and optimize Mastercam programs for multi-axis CNC equipment.
Develop and optimize robotic machining processes, including toolpaths, positioning, reach and accessibility, collision avoidance, spindle orientation, cutting parameters, and robot motions.
Support production and continuous improvement of KUKA robotic machining cells, including program prove-out, fixture setup, coordinate systems, tooling, machining parameters, dimensional verification, and troubleshooting.
Account for robotic machining characteristics such as stiffness, accuracy, repeatability, dynamic loading, reach limitations, singularities, and process-induced deflection.
Develop part locating, fixturing, datum, and workholding strategies that maintain dimensional accuracy and prevent damage, distortion, or excessive loading.
Optimize tools, cutting parameters, and toolpaths to minimize composite machining defects, heat and surface damage, and excessive tool wear.
Establish and improve machining parameters and tool-life management and cutter-replacement strategies.
Support implementation, qualification, and improvement of CNC routers, machining centers, robotic systems, probing systems, vacuum workholding, and supporting production equipment.
Evaluate machine and robot capability, accuracy, repeatability, and process capability against engineering tolerances and production requirements.
Troubleshoot robotic machining issues involving programming, simulation, robot motion, spindle orientation, coordinate systems, fixture alignment, cutter engagement, vibration, dimensional variation, and cell performance.
Own machining hardware and production processes from development through full-rate production, ensuring safety, quality, cost, and schedule requirements are met.
Provide hands-on manufacturing-floor support and troubleshoot machine, robot, tooling, programming, workholding, and part-related issues.
Develop work instructions, setup documentation, machining procedures, tool lists, inspection requirements, and process specifications.
Interpret engineering drawings, GD&T, CAD models, and inspection data to develop processes that consistently meet dimensional requirements.
Collaborate with Design Engineering on design for manufacturability and machining, including tolerance strategy, datum structure, trim definitions, hole requirements, and tool accessibility.
Lead investigation and resolution of machining nonconformances using structured root-cause analysis and corrective and preventive actions.
Identify and resolve dimensional variation, machining defects, tool wear, fixture variation, equipment performance, programming, and process-stability issues.
Establish and improve robotic machining process capability for large composite trimming, drilling, routing, and milling.
Identify opportunities for machining automation, probing, setup verification, in-process inspection, digital work instructions, and data-driven process control.
Support capital equipment selection and implementation, including technical requirements, evaluation, acceptance testing, installation, qualification, and production readiness.