Application Engineering Manager - Wire EDM

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

Benefits offered by this job

Medical, Dental, Vision

Paid time off

Education Assistance

401(k) Plan

Career growth opportunities

Job summary

Methods Machine Tools, Inc. is seeking an Application Engineering Manager to oversee all Wire EDM applications engineering activities in Sudbury, MA. The role requires a deep expertise in FANUC Robocut machines and a focus on customer engagement, technical proposals, and developing turnkey solutions.

The ideal candidate should have over 10 years of Wire EDM experience including leadership skills and proficiency in CNC programming. The position offers a competitive salary and benefits package.

Qualifications

• 10+ years of Wire EDM experience, including 3 years in a supervisory role.
• Strong knowledge of electrical discharge machining principles.
• Experience with automation integration for Wire EDM.

Responsibilities

• Manage Wire EDM applications engineering activities.
• Lead a team of applications engineers.
• Develop turnkey Wire EDM solutions.

Skills

FANUC Robocut expertise

CNC programming

EDM process optimization

Customer engagement

Leadership and management

Education

Bachelor’s degree in Mechanical Engineering

Tools

CAD/CAM software

FANUC CNC controls

Job description

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
• 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

Equal Opportunity/Affirmative Action

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.