Composites Machining Manufacturing Engineer II

Job Description

ABOUT Firefly Aerospace is a space and defense technology company on a mission to reliably and repeatedly launch land and operate space systems from Earth to the Moon and beyond As the partner of choice for critical space missions Firefly is the first commercial company to launch a satellite to orbit with 24 hour notice and the first company to achieve a successful Moon landing Headquartered in north Austin Texas Firefly is looking for passionate hardworking innovators to join our team and help fuel our successful trajectory into space SUMMARY We are seeking a highly motivated and dedicated Composite Machining Manufacturing Engineer to join our Structures Department As part of a small fast paced and passionate team you will be instrumental in developing and scaling the manufacturing processes required to produce advanced composite aerospace structures You will be responsible for developing implementing and continuously improving machining processes for carbon fiber composite components including CNC routing trimming drilling profiling and other secondary machining operations You will own machining processes from initial development through full rate production develop tooling and workholding solutions support CNC and robotic machining programming and provide technical expertise to ensure parts meet demanding quality cost and schedule requirements This role will support a manufacturing environment utilizing Mastercam for CNC programming Mastercam and Robotmaster for robotic machining programming and KUKA industrial robotic machining cells in addition to conventional multi axis CNC equipment This position requires a strong background in aerospace manufacturing composite machining CNC and robotic machining equipment practical problem solving and the ability to quickly become an expert on complex hardware and manufacturing systems RESPONSIBILITIES Lead the development and implementation of machining processes for aerospace composite components including trimming routing drilling milling profiling countersinking and other secondary machining operationsDevelop and optimize machining strategies for carbon fiber reinforced polymer CFRP sandwich structures honeycomb core foam core bonded assemblies and other composite configurationsDevelop CNC manufacturing processes including cutter selection feeds and speeds toolpath strategy workholding datum strategy probing inspection and process controlsDevelop review simulate prove out and optimize CNC machining programs using Mastercam for multi axis CNC equipmentDevelop and optimize robotic machining processes including toolpath strategy robot positioning reach and accessibility collision avoidance spindle orientation cutting parameters approachretract motions and off part movementSupport production operation and continuous improvement of KUKA robotic machining cells including program prove out fixture setup coordinate system establishment tooling machining parameters dimensional verification and troubleshootingDevelop machining strategies that account for the unique characteristics of robotic machining including robot stiffness positional accuracy repeatability dynamic loading tool orientation reach limitations singularities and process induced deflectionDevelop robust part locating fixturing datum and workholding strategies that maintain dimensional accuracy while preventing damage distortion or excessive loading of composite hardwareOptimize cutter selection cutting parameters and toolpath strategies to minimize delamination fiber breakout splintering heat damage surface damage excessive tool wear and other composite machining defectsEstablish and continuously improve machining parameters including spindle speed feed rate depth of cut cutter geometry entry and exit strategy drilling strategy and tool life requirementsDevelop and implement tool life management and cutter replacement strategies to maintain consistent machining quality and reduce manufacturing riskSupport implementation qualification and continuous improvement of CNC routers machining centers KUKA robotic machining systems probing systems vacuum workholding systems and supporting production equipmentEvaluate machine and robot capability accuracy repeatability and process capability to ensure equipment can meet engineering tolerances and production requirementsTroubleshoot robotic machining issues involving Mastercam toolpaths Robotmaster simulation or output KUKA robot motion spindle orientation work coordinate systems fixture alignment cutter engagement vibration dimensional variation and robotic cell performanceAct as the manufacturing engineering subject matter expert and primary point of contact for composite machining operations and assigned hardwareTake ownership of machining hardware and production processes from development through full rate production ensuring adherence to safety quality cost and schedule requirementsProvide hands on manufacturing floor support during machining operations troubleshooting machine robot tooling programming workholding and part related issuesDevelop detailed work instructions setup documentation machining procedures tool lists inspection requirements and process specifications to standardize production operationsInterpret engineering drawings GD\&T requirements CAD models and inspection data to develop manufacturing processes capable of consistently meeting dimensional requirementsCollaborate closely with Design Engineering to improve design for manufacturability and design for machining including tolerance strategy datum structure trim definitions hole requirements and tool accessibilityLead the investigation and resolution of machining related nonconformances through structured root cause analysis and implementation of effective corrective and preventive actionsIdentify and resolve issues involving dimensional variation machining defects tool wear fixture variation machine performance robotic performance programming and process instabilityEstablish and continuously improve robotic machining process capability particularly for large composite trimming drilling routing and milling operationsIdentify opportunities for machining automation probing automated setup verification in process inspection digital work instructions and data driven process controlSupport capital equipment selection and implementation including development of technical requirements equipment evaluation acceptance testing installation qualification and production readinessQUALIFICATIONS Required Bachelors degree in Mechanical Engineering Manufacturing Engineering Aerospace Engineering or a related engineering fieldSignificant experience in aerospace manufacturing with demonstrated experience in composite machining CNC manufacturing robotic machining or advanced structures manufacturingStrong understanding of carbon fiber composite materials and the unique challenges associated with machining composite structuresHands on experience developing or supporting CNC routing trimming drilling milling or other machining processesStrong understanding of CNC machining principles cutting tools feeds and speeds workholding fixturing machine setup and manufacturing process developmentExperience interpreting engineering drawings CAD models tolerances and GD\&TStrong technical aptitude and ability to quickly become an expert on complex aerospace hardware and manufacturing equipmentProficiency with CADCAM software for reviewing hardware and developing manufacturing processes tooling and fixturingDemonstrated ability to troubleshoot complex manufacturing issues using structured problem solving and root cause analysis techniquesExperience supporting manufacturing operations in a production environment and working directly with machinists technicians programmers and production personnelExcellent communication skills and ability to collaborate effectively with cross functional engineering and manufacturing teamsDemonstrated track record of driving process improvements and delivering measurable improvements in quality cost throughput or scheduleHigh level of initiative self motivation and ability to thrive in a dynamic and fast paced aerospace manufacturing environmentExcellent analytical and problem solving abilitiesDesired 5 years of experience in aerospace manufacturing machining manufacturing engineering or a related engineering environmentExperience machining CFRP fiberglass honeycomb sandwich panels Rohacell or other foam core structures bonded composite assemblies and large composite structuresExperience programming or supporting 3 axis and 5 axis CNC routers or machining centersHands on experience with Mastercam for multi axis CNC machining and toolpath developmentExperience with Robotmaster for offline robot programming simulation collision detection reach analysis and robot code generationExperience programming proving out or supporting KUKA industrial robotic machining systemsExperience developing machining workflows utilizing Mastercam Robotmaster KUKA robotic machining cellsExperience with robotic trimming drilling routing and milling of large aerospace composite structuresUnderstanding of industrial robot kinematics and the differences between conventional CNC machining and robotic machining including robot stiffness accuracy repeatability reach singularities compliance and dynamic responseExperience integrating KUKA robots with external machining spindles tooling systems workholding systems and production equipmentExperience establishing and validating Tool Center Points TCP work coordinate systems fixture coordinate systems robot calibration and part localization for robotic machiningExperience troubleshooting robotic machining programs involving tool orientation reach singularities collision conditions motion transitions and machining induced deflectionExperience with CNC probing and automated part setup systems including Renishaw or similar probing technologiesExperience developing vacuum fixtures composite machining fixtures drill fixtures and large part workholding systemsExperience with machine tool and robotic cell accuracy calibration volumetric compensation and process capability studiesExperience with automated tool setters cutter life monitoring and machining process automationExperience with metrology and inspection systems including CMMs laser trackers portable measurement arms or 3D inspection softwareUnderstanding of machine code and robotic programming concepts including G code cutter compensation work coordinate systems tool offsets probing cycles TCPs and multi axis machiningExperience developing machining processes for large aerospace structures and tight tolerance composite componentsExperience implementing new CNC equipment or robotic manufacturing cells from requirements development through production qualificationExperience with Lean Manufacturing Six Sigma PFMEA control plans SPC and structured root cause analysisSix Sigma or Lean Manufacturing certificationMasters degree in Mechanical Manufacturing or Aerospace Engineering is a plusFirefly offers outstanding benefits for our employees including generous health dental and vision plans with low plan deductibles parental leave educationalrelocation reimbursement short term disability and flexible PTO options To conform to US Government space technology export regulations including the International Traffic in Arms Regulations ITAR you must be a US citizen lawful permanent resident of the US protected individual as defined by 8 USC 1324ba3 or eligible to obtain the required authorizations from the US Department of State Firefly Aerospace Inc is an Equal Opportunity Employer; employment with Firefly is governed based on merit competence and qualifications and will not be influenced in any manner by race color religion gender national originethnicity veteran status disability status age sexual orientation gender identity marital status mental or physical disability or any other legally protected status