Application Engineering Manager - Wire EDM

Methods, Inc.; Sudbury (MA); On-site; USD 139,108 - 180,840; Full time

Benefits offered by this job

Medical insurance

Dental insurance

Vision insurance

Paid time off

Education Assistance

401(k) Plan

Job summary

Methods, Inc. is seeking an Application Engineering Manager specializing in Wire EDM based in Sudbury, MA. The role involves hands-on leadership in managing Wire EDM applications, overseeing a team, and providing expert support in FANUC Robocut technology.

The ideal candidate will have deep expertise in wire EDM processes, technical consultation, and a robust understanding of CAD/CAM software. This position offers excellent career growth potential and includes benefits such as medical, dental, and 401(k).

Qualifications

• 10+ years of experience in Wire EDM applications.
• Strong leadership and team management abilities.
• Experience with CAM-I is highly preferred.

Responsibilities

• Manage all Wire EDM applications engineering activities.
• Develop and optimize cutting parameters across materials.
• Conduct on-site customer training and support.

Skills

FANUC Robocut platforms knowledge

Expert understanding of wire EDM principles

G & M code programming

Excellent communication skills

Education

Bachelor’s degree in Mechanical Engineering or related discipline

Tools

CAD/CAM software

Mastercam

Esprit

Job description

# Application Engineering Manager – Wire EDM**Job Title**: Application Engineering Manager**Department**: Application Engineering**Location**: Sudbury, MA---## About MethodsMethods 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 OVERVIEWThe 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 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 responsibility*** Recruit, develop, and manage a team of Wire EDM applications engineers, setting performance goals and conducting regular evaluations* Establish training programs to ensure the team maintains current knowledge of FANUC Robocut technology, new product releases, and evolving EDM best practices* Allocate engineering resources across pre-sales support, post-sales installation, customer training, and ongoing technical support activities* Supervise geographically dispersed direct reports, ensuring operational efficiency and adherence to organizational policies.**Travel Requirements:*** Willingness to travel up to 30% domestically, with occasional international travel**Physical Requirements:*** Ability to stand, walk, and work on the shop floor for extended periods* Ability to lift up to 50 lbs**Salary Description**$139,108.48 – $180,840.92**Additional Information**This job description is designed to provide an overview of basic skills, experiences and education required to perform the job and is not designed to cover or contain a comprehensive listing of all activities, duties, or responsibilities required of the employee to perform the essential functions of the job. In instances where educational degrees are required, the company will take into consideration factors such as additional experience, training, or certifications in lieu of specific educational requirements*.****Methods Machine is an Equal Opportunity/Affirmative Action employer. All qualified applicants will receive consideration for employment without regard to sex, gender identity, sexual orientation, race, color, religion, national origin, disability, protected Veteran status, age, or any other characteristic protected by law.***