Applications Engineering Manager - Wire EDM

Description

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.

Job Responsibilities:

Technical Leadership

* 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

Customer Engagement

* 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

Process & Strategy

* 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

Required Skills/Abilities:

* 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

Minimum

Education and Experience:

* 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

* 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

Supervisory Responsibilities:

* Recruit, develop, and manage a team of Wire EDM applications engineers, setting performance goals and…