Application Engineering Manager - Wire EDM

# Application Engineering Manager – Wire EDM
** Job Title**:
Application Engineering Manager
** Department**:
Application Engineering
** Location**:
Sudbury, MA---## About Methods Methods Machine Tools supplies high-quality, high-precision machine tools and automation solutions, and designs integrated custom machining processes and systems. Headquartered in Sudbury, Mass., and in operation since 1958, Methods provides an end-to-end portfolio of best-in-class products, engineering, service, parts, training, and integration. Methods has more than 300 employees, seven technology centers, one high precision machining center, and has installed in excess of 45,000 machines throughout North America.

---## POSITION OVERVIEW 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.
** Benefits:
*** Medical, Dental, Vision, Paid time off, Education Assistance, 401(k) Plan, and great opportunity for career growth.##

Key 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…