Lead Applications Engineer - Aerospace Center of Excellence

Company Description For over 50 years, DN Solutions has built machine tools that shape the world around us, including the cars we drive, the planes we fly, and the medical devices that save lives. We develop smart machines and customized solutions that advance these essential industries.

Join our applications engineering team and help customers put advanced mill-turn technology to work.

Job Description The Lead Applications Engineer for the Aerospace Center of Excellence leads the development and demonstration of advanced machining processes for aerospace and defense customers. Based at the Chicago Technical Center, this person directs technical work across customer evaluations, turnkey projects, test cuts, and production validation. The role is hands-on: the lead programs and proves out difficult parts while guiding other engineers and coordinating with DN Solutions and HELLER technical teams.

Job Responsibilities Set technical priorities for aerospace applications and guide engineers through process planning, programming, prove-out, validation, and customer handoff.

Lead customer projects from part review and feasibility through machine selection, process design, programming, test cutting, validation, acceptance, and production startup.

Develop multi-axis milling strategies for complex aerospace and defense components, including difficult materials, tight tolerances, and demanding surface requirements.

Select and validate cutting tools, fixtures, probing, inspection methods, and automation concepts to achieve quality, cycle-time, and production requirements.

Program, set up, and prove out applications on DN Solutions and HELLER machines as appropriate to the project.

Establish repeatable methods for documenting cycle times, setups, tooling, quality results, lessons learned, and other key application data.

Mentor aerospace applications engineers and review technical work to ensure consistent quality, technical execution, and on-time delivery.

Collaborate with HQ Applications Engineering, R&D, HELLER, product management, sales, service, and customers on machine capabilities, technical requirements, new technologies, and demonstrations.

Coordinate project schedules, technical risks, deliverables, customer communications, and technical presentations, including pre-sale evaluations, cycle-time studies, proposals, demonstrations, and customer visits.

Support customer implementation through production optimization, personnel training, and technical events, including open houses and trade shows, while representing the COE and presenting validated process recommendations and results.

Job Requirements Required At  least 10 years of experience in CNC machining, manufacturing engineering, or applications engineering, including substantial aerospace machining experience.

Demonstrated ability to develop, program, set up, and validate complex 3-, 4-, and 5-axis machining processes.

Experience machining difficult materials such as titanium, Inconel, and stainless steels, with strong knowledge of tooling and work holding.

Ability to interpret aerospace drawings, CAD models, GD&T, and customer quality requirements.

Proficiency with CAD/CAM software, G-code troubleshooting, machining simulation, and cycle-time analysis.

Experience leading technical projects and coaching other engineers; strong communication with customers and cross-functional teams.

Bachelor’s degree in mechanical, manufacturing, aerospace, or industrial engineering, or equivalent relevant experience.

Preferred Experience with DN Solutions or HELLER machining centers and their control platforms.

Experience with Siemens NX, hyperMILL, Mastercam, VERICUT, or comparable CAM and verification tools.

Experience with aerospace and defense customer…