Special Process Engineer - Non-Conventional Machining

Pursuit Aerospace-posted 3 months ago
Full-time • Mid Level
Manchester, CT
1,001-5,000 employees
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We are seeking a skilled and innovative Special Process - Non-Conventional Machining (NCM) Engineer to support and optimize advanced machining processes including Laser machining, EDM (Wire), and other non-traditional methods. The Special Process - NCM Engineer will play a critical role in developing, qualifying, and maintaining processes that meet stringent aerospace and precision manufacturing standards.

  • Develop and optimize non-conventional machining processes (e.g., Laser cutting/drilling, Wire EDM, for new and existing components
  • Work closely with design engineering to ensure manufacturability and process feasibility
  • Program and set parameters for Laser and EDM machines to achieve dimensional and metallurgical requirements
  • Define and document machining process flows, tooling, fixtures, and quality checkpoints
  • Lead process qualifications and validations, including capability studies (CP, CPK) and first article inspections (FAI)
  • Collaborate with Quality and Special Process teams to meet NADCAP, AS9100, and customer-specific requirements
  • Drive root cause analysis and continuous improvement in response to process deviations or quality issues
  • Select and manage suppliers or subcontractors for outsourced NCM processes
  • Train operators and technicians on safe and effective use of non-conventional machining equipment
  • Stay current with industry trends, technologies, and best practices in advanced machining
  • Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, or related field AND 3+ years of experience in non-conventional machining (Laser, EDM, ECM, etc.) – OR – in lieu of degree, 7+ years of experience in non-conventional machining (Laser, EDM, ECM, etc.)
  • 2+ years of experience in a manufacturing or quality engineering role
  • Must be authorized to work in the U.S. on a full-time basis without sponsorship now or in the future.
  • Must be able to perform work subject to ITAR/EAR regulations.
  • Hands-on experience with programming and operating Laser/EDM equipment (e.g., subishi, Sodick, FANUC, Trumpf, etc.)
  • Strong understanding of material behavior during high-energy machining processes
  • Experience with process documentation and validation (FAI, PPAP, control plans)
  • Ability to read and interpret complex engineering drawings and GD&T
  • Familiarity with special process audits and NADCAP accreditation requirements
  • Lean or Six Sigma certification
  • Knowledge of CNC, CMM, and precision inspection tools
  • Proficiency in CAD/CAM software (e.g., Mastercam, Siemens NX, SolidWorks)
  • Aerospace experience is preferred.
  • Health and disability insurance
  • 401(k) match
  • Flexible spending accounts
  • EAP
  • Paid time off
  • Company-paid holidays
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