Applications Engineering Manager – Wire EDM

Applications Engineering Manager – Wire EDM

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.

• 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

• 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

• 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…