Composite Machining Manufacturing Engineer

DIRECT HIRE: The Composite Machining Manufacturing Engineer develops, implements, and improves machining processes for advanced aerospace composite structures. This role supports manufacturing from initial process development through production qualification and full-rate production, with an emphasis on CNC machining, robotic machining, tooling, fixturing, process optimization, and quality control. The engineer works closely with design engineering, programmers, machinists, technicians, and production teams to deliver complex composite components that meet stringent dimensional, quality, cost, and schedule requirements.

Location: North Austin, Texas
Salary Range: $95K - $125K

• Develop and optimize machining processes for carbon fiber reinforced polymer (CFRP), fiberglass, honeycomb sandwich panels, foam-core structures, bonded assemblies, and large aerospace composite components

• Establish manufacturing strategies for CNC routing, trimming, drilling, milling, profiling, countersinking, and other secondary machining operations

• Develop, simulate, prove out, and optimize multi-axis CNC programs using Mastercam, selecting appropriate cutters, toolpaths, feeds, speeds, cutting depths, and machining sequences

• Support offline robotic machining programming using Robot master and KUKA industrial robotic systems, including toolpath development, reach analysis, collision detection, robot motion, and program validation

• Develop reliable work holding, vacuum fixtures, drill fixtures, datum structures, and coordinate systems to maintain part accuracy while preventing composite damage or distortion

• Establish and validate tool center points (TCPs), work and fixture coordinate systems, robot calibration, part localization, and probing routines for accurate CNC and robotic machining

• Troubleshoot manufacturing issues involving toolpaths, robot positioning, machine accuracy, vibration, tooling, fixture alignment, dimensional variation, and process instability

• Optimize machining parameters and tool-life management to reduce delamination, fiber breakout, splintering, heat damage, surface defects, and excessive cutter wear

• Evaluate CNC machines, robotic cells, probing systems, and supporting equipment for accuracy, repeatability, capability, and production readiness

• Provide hands-on manufacturing floor support, partnering with machinists, technicians, programmers, and production personnel to resolve equipment and process issues

• Interpret engineering drawings, CAD models, GD&T requirements, and inspection results to develop processes that consistently meet dimensional and quality specifications

• Collaborate with Design Engineering to improve design for manufacturability, including tolerances, datum structures, trim definitions, hole requirements, and tool accessibility

• Lead root-cause investigations and corrective actions for machining defects, nonconformances, tool wear, dimensional issues, and equipment performance problems

• Create and maintain manufacturing documentation, including work instructions, setup procedures, tooling lists, inspection requirements, machining standards, and process specifications

• Identify opportunities for automation, probing, in-process inspection, automated setup verification, digital work instructions, and data-driven process controls

• Support capital equipment projects from technical requirements and vendor evaluations through acceptance testing, installation, qualification, and production launch

• Drive continuous improvement initiatives that improve safety, quality, throughput, cost, equipment utilization, and manufacturing consistency

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Aerospace Engineering, or a related engineering discipline

• Significant experience in aerospace manufacturing, composite machining, CNC manufacturing, robotic machining, or advanced structures manufacturing

• Strong understanding of carbon fiber composites and the challenges associated with machining composite materials

• Hands-on experience developing or supporting CNC routing, trimming, drilling, milling, or related machining processes

• Knowledge of cutting tools, feeds and speeds, toolpaths, work holding, fixturing, machine setup, and manufacturing process development

• Ability to interpret engineering drawings, CAD models, dimensional tolerances, and GD&T requirements

• Proficiency with CAD/CAM software for reviewing hardware and developing manufacturing processes, tooling, and fixtures

• Strong…