Applications Engineer

Kelaca; Danville (VA); On-site; USD 90,000 - 140,000; Full time

Benefits offered by this job

Competitive benefits

Retirement support

Paid time off

Professional development

Job summary

Kelaca in Virginia seeks an CMA Applications Engineer to support advanced manufacturing across multi-axis and 5-axis machining, additive and metrology within the CMA Center for Manufacturing Advancement.

You will design manufacturable solutions from incomplete requirements and translate them into CNC programs, fixturing and inspection approaches, with clear documentation; you will also help rebalance workload and mentor a skilled applications team from concept through prove-out.

Qualifications

• Core requirements: CNC programming—extensive multi-axis/5-axis; CAD/CAM expertise with high-end CAM tools; precision machining and process design; multi-axis capabilities; cutting tools knowledge; workholding and fixturing; inspection/metrology integration; regulated manufacturing experience; general software tools.

Responsibilities

• Program and support setup and operation of advanced CNC equipment (multi-axis/5-axis mills, mill/turn, dual spindle lathes, tooling systems).
• Lead tooling, workholding and CNC technology implementations for new and existing projects.
• Design, validate and optimize robust CNC processes for high-accuracy work emphasizing safety, quality and throughput.
• Integrate new subtractive/additive/inspection/IoT technologies to improve capability and efficiency.
• Collaborate with engineering, machining, metrology/NDT and operations to plan subtraction/inspection activities.

Skills

CNC programming

CAD/CAM

Precision machining

Multi-axis machining

Cutting tools

Workholding

Inspection and metrology

Regulated manufacturing

General tools & systems

Tools

Siemens NX

Mastercam

Job description

The CMA Applications Engineer supports advanced manufacturing work across multi-axis and 5-axis machining, additive and subtractive processes, metrology/NDT and Industry 4.0 within the Center for Manufacturing Advancement (CMA) and an associated Center of Excellence.

This role focuses on developmental work where the manufacturing route is not yet defined. Starting from incomplete or first-of-a-kind requirements, you will design manufacturable solutions and translate them into CNC programs, fixturing and tooling strategies, inspection approaches and clear documentation. You will also help rebalance workload across a small, highly skilled applications team by owning complex work from concept through prove out.

Key responsibilities:

• Program and support setup and operation of advanced CNC equipment, including multi-axis and 5-axis mills, mill/turn machines, dual spindle lathes, tool presetting systems and selected additive platforms.
• Lead implementation of tooling, workholding and CNC technologies for new and existing projects.
• Design, validate and optimize robust CNC processes for complex, highaccuracy work with a focus on safety, repeatability, quality and throughput.
• Integrate new subtractive, additive, inspection and data/IoT technologies where they improve capability, efficiency or quality.
• Collaborate with engineering, machining, metrology/NDT and operations teams to plan and execute subtractive manufacturing and inspection activities.
• Ensure work complies with applicable data privacy, quality and regulatory standards (e.g. ITAR, ISO, ANSI).
• Produce clear technical documentation, procedures and workflows to support traceability, training and audit.
• Track key process data (e.g. parameters, inspection results, lessons learned) and feed insights into continuous improvement.
• Balance emergent customer requests with longer term optimization work.
• Participate in onsite and offsite customer and stakeholder meetings, including visits to customer facilities to investigate problems, present solution options and support implementation.
• Perform other related duties in support of the Center’s technical and commercial objectives.

Knowledge, skills and experience:

Core requirements:

• CNC programming - Extensive CNC programming experience required, including complex multi-axis and 5-axis work. Demonstrated ability to create programs that can run reliably and safely for recurring developmental or production work, not just one-off parts.
• CAD/CAM - Extensive CAD/CAM experience and knowledge required. Hands-on programming experience in a high-end CAM environment such as Siemens NX (or similar) strongly preferred as the primary tool chain for regulated work.
• Precision machining and process design - Deep working knowledge of precision machining principles, tight tolerances, material behavior and process stability in high accuracy environments. Proven ability to design machining sequences that balance quality, cycle time, risk and cost.
• Multi-axis machining - Significant experience with multi-axis and 5-axis machining, dual spindle lathes and mill/turn equipment, including programming, setup, prove out and optimization.
• Cutting tools - Strong knowledge of cutting tools, materials and applications, including tool selection, tool life management and process optimization.
• Workholding and fixturing - Extensive experience with workholding techniques and fixture design, with a track record of safe, rigid, efficient and repeatable setups.
• Inspection and metrology - Knowledge of pre, in and post process inspection methods and how they integrate with machining strategies; familiarity with using macro variable programming and similar techniques within CNC programs to support process control.
• Regulated manufacturing compliance - Experience working under, or strong familiarity with, ITAR, ISO and ANSI expectations in manufacturing environments and how they affect documentation, process control and data handling.
• General tools and systems - Proficiency with Microsoft Office (or equivalent) and comfort working within digital job management, data collection and reporting tools.

Preferred or nice-to-have:

• Programming experience specifically in Siemens NX for multi-axis/5-axis work in regulated
• Experience with Mastercam or other advanced CAM tools.
• Experience with metal additive manufacturing processes and how additive choices impact
• downstream machining and inspection.
• Broader knowledge of additive manufacturing technologies and dimensional inspection/metrology tooling (e.g. CMM, advanced gauging, NDT concepts).
• Exposure to ancillary machining processes (e.g. EDM, grinding) and how they complement CNC machining.
• Experience with SPC, process monitoring and data collection systems, and using data to improve process design.
• Familiarity with IoT/Industry 4.0 concepts in manufacturing (connected machines, data flows, dashboards, basic analytics).
• Prior customer facing technical experience such as onsite problem investigation, solution delivery or technical presentations.

Why apply?

This is an onsite role in a modern, advanced manufacturing environment where engineering work is tightly connected to real equipment, materials and customer outcomes. The work is varied and challenging: one week may focus on solving a new manufacturing problem for a strategic customer; the next may involve refining and documenting processes that others will run at scale. You will:

• Work on visible, high impact programs across both defense and commercial customers.
• Help shape how CNC, additive, metrology and data/IoT technologies are applied in a growing Center for Manufacturing Advancement and an associated new facility.
• Play a direct role in mentoring and developing machinists and future engineers.
• Have access to professional development opportunities, both technical (new technologies, processes, tools) and soft-skill oriented (communication, leadership, customer interaction).
• Join a team that is expanding, with plans to add new facilities and intermediate leadership roles as the engineering organization grows.

The total rewards package includes competitive benefits, retirement support, paid time off and professional development opportunities, combined with the stability and resources of an established institution.