Applications Engineering Manager Wire EDM

Swift Placement & Consulting; Sudbury (MA); On-site; USD 139,000 - 181,000; Full time

Job summary

Swift Placement & Consulting seeks an Applications Engineering Manager for Wire EDM to lead and guide a team of engineers focused on FANUC Robocut systems. You will drive turnkey solutions, optimize cutting processes, and provide pre‑ and post‑sales technical support to customers across industries.

The role demands deep Wire EDM knowledge, CAM/CAD proficiency, and strong leadership and communication skills, enabling collaboration with sales and manufacturing teams.

Qualifications

• Bachelor's degree in Mechanical or Manufacturing Engineering or equivalent
• 10+ years of progressive Wire EDM experience, 8+ in supervision
• Strong leadership and communication skills

Responsibilities

• Lead Wire EDM technical authority with FANUC Robocut platforms
• Develop cutting parameters and machining processes across materials
• Guide FANUC controls, iHMI, AWF3, iPulse3 and related features
• Lead turnkey Wire EDM solutions including fixturing and automation
• Conduct on-site and in-house training and demonstrations
• Recruit and manage a team of applications engineers and plan workload

Skills

FANUC Robocut

G&M code

Automation integration

Leadership

Education

Bachelor's degree in Mechanical/Manufacturing Engineering

Tools

CAM software

CAD/CAM

Mastercam

Esprit

Job description

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.

Can also live near Wixom, MI or Gilberts, IL

Job 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 Responsibilities:

• 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:

$139,108.48 - $180,840.92

#ZR

Compensation:

$170,000 per year