Composite Machining Manufacturing Engineer

SST Direct; Austin (TX); On-site; USD 95,000 - 125,000; Full time

Job summary

SST Direct seeks a Composite Machining Manufacturing Engineer to develop, implement, and improve machining processes for aerospace composite structures in North Austin. You’ll support from development to full-rate production, focusing on CNC and robotic machining, tooling, fixturing, and process control.

You will collaborate with design and production teams to meet stringent dimensional, quality, cost, and schedule requirements, driving root-cause investigations and continuous improvements in a

Qualifications

• Bachelor's degree in Mechanical, Manufacturing, Aerospace or related engineering discipline.
• Significant aerospace manufacturing experience focusing on composite machining.
• Strong understanding of carbon fiber composites and machining challenges.
• Hands-on experience with CNC routing, trimming, drilling, milling, or related processes.
• Knowledge of cutting tools, feeds/speeds, toolpaths, fixturing, machine setup.
• Ability to interpret drawings, CAD models, GD&T requirements, and tolerances.
• Proficiency with CAD/CAM software for tooling and fixtures.
• Experience with cross-functional collaboration in a fast-paced environment.

Responsibilities

• Develop and optimize machining processes for CFRP, fiberglass, honeycomb panels, and large aerospace components.
• Establish strategies for CNC routing, trimming, drilling, milling, and secondary ops.
• Develop and optimize multi-axis CNC programs using Mastercam; select cutters, toolpaths, feeds, speeds.
• Support offline robotic machining programming using Robotmaster and KUKA systems.
• Develop workholding, fixtures, datum structures, and coordinate systems to preserve part accuracy.
• Validate TCPs, coordinate systems, robot calibration, and probing routines for accuracy.
• Troubleshoot toolpaths, robot positioning, machine accuracy, and process stability.
• Drive continuous improvement to reduce delamination, defects, wear, and costs.

Skills

Troubleshooting

Analytical thinking

Communication

Root cause analysis

Team collaboration

Education

Bachelor's degree in Mechanical Engineering / Manufacturing Engineering / Aerospace Engineering

Master's degree in Mechanical / Manufacturing / Aerospace Engineering

Tools

Mastercam

Robotmaster

KUKA robotics

Renishaw probing systems

CAD/CAM software

Job description

DIRECT HIRE: The Composite Machining Manufacturing Engineer develops, implements, and improves machining processes for advanced aerospace composite structures. This role supports manufacturing from initial process development through production qualification and full-rate production, with an emphasis on CNC machining, robotic machining, tooling, fixturing, process optimization, and quality control. The engineer works closely with design engineering, programmers, machinists, technicians, and production teams to deliver complex composite components that meet stringent dimensional, quality, cost, and schedule requirements.

Location: North Austin, Texas
Salary Range: $95K - $125K

Key Responsibilities:

• Develop and optimize machining processes for carbon fiber reinforced polymer (CFRP), fiberglass, honeycomb sandwich panels, foam-core structures, bonded assemblies, and large aerospace composite components

• Establish manufacturing strategies for CNC routing, trimming, drilling, milling, profiling, countersinking, and other secondary machining operations

• Develop, simulate, prove out, and optimize multi-axis CNC programs using Mastercam, selecting appropriate cutters, toolpaths, feeds, speeds, cutting depths, and machining sequences

• Support offline robotic machining programming using Robotmaster and KUKA industrial robotic systems, including toolpath development, reach analysis, collision detection, robot motion, and program validation

• Develop reliable workholding, vacuum fixtures, drill fixtures, datum structures, and coordinate systems to maintain part accuracy while preventing composite damage or distortion

• Establish and validate tool center points (TCPs), work and fixture coordinate systems, robot calibration, part localization, and probing routines for accurate CNC and robotic machining

• Troubleshoot manufacturing issues involving toolpaths, robot positioning, machine accuracy, vibration, tooling, fixture alignment, dimensional variation, and process instability

• Optimize machining parameters and tool-life management to reduce delamination, fiber breakout, splintering, heat damage, surface defects, and excessive cutter wear

• Evaluate CNC machines, robotic cells, probing systems, and supporting equipment for accuracy, repeatability, capability, and production readiness

• Provide hands-on manufacturing floor support, partnering with machinists, technicians, programmers, and production personnel to resolve equipment and process issues

• Interpret engineering drawings, CAD models, GD&T requirements, and inspection results to develop processes that consistently meet dimensional and quality specifications

• Collaborate with Design Engineering to improve design for manufacturability, including tolerances, datum structures, trim definitions, hole requirements, and tool accessibility

• Lead root-cause investigations and corrective actions for machining defects, nonconformances, tool wear, dimensional issues, and equipment performance problems

• Create and maintain manufacturing documentation, including work instructions, setup procedures, tooling lists, inspection requirements, machining standards, and process specifications

• Identify opportunities for automation, probing, in-process inspection, automated setup verification, digital work instructions, and data-driven process controls

• Support capital equipment projects from technical requirements and vendor evaluations through acceptance testing, installation, qualification, and production launch

• Drive continuous improvement initiatives that improve safety, quality, throughput, cost, equipment utilization, and manufacturing consistency

Required Qualifications:

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Aerospace Engineering, or a related engineering discipline

• Significant experience in aerospace manufacturing, composite machining, CNC manufacturing, robotic machining, or advanced structures manufacturing

• Strong understanding of carbon fiber composites and the challenges associated with machining composite materials

• Hands-on experience developing or supporting CNC routing, trimming, drilling, milling, or related machining processes

• Knowledge of cutting tools, feeds and speeds, toolpaths, workholding, fixturing, machine setup, and manufacturing process development

• Ability to interpret engineering drawings, CAD models, dimensional tolerances, and GD&T requirements

• Proficiency with CAD/CAM software for reviewing hardware and developing manufacturing processes, tooling, and fixtures

• Strong troubleshooting, analytical, communication, and root-cause-analysis skills

• Experience supporting production operations and collaborating with cross-functional engineering and manufacturing teams

• Demonstrated ability to improve quality, cost, throughput, or schedule performance in a fast-paced manufacturing environment

Preferred Qualifications:

• 5+ years of experience in aerospace manufacturing, machining, manufacturing engineering, or a related technical environment

• Experience machining CFRP, fiberglass, honeycomb, Rohacell or other foam-core structures, bonded composite assemblies, and large composite components

• Experience programming or supporting 3-axis and 5-axis CNC routers or machining centers

• Hands-on experience with Mastercam multi-axis programming and Robotmaster offline robotic programming, simulation, and code generation

• Experience programming, proving out, and troubleshooting KUKA robotic machining cells and integrated spindle systems

• Understanding of robotic machining limitations, including stiffness, accuracy, repeatability, reach, singularities, compliance, and dynamic response

• Experience with Renishaw or similar probing systems, automated tool setters, cutter-life monitoring, and machining automation

• Experience with machine and robot calibration, volumetric compensation, process capability studies, and large-part workholding

• Familiarity with CMMs, laser trackers, portable measurement arms, or 3D inspection software

• Knowledge of G-code, cutter compensation, work offsets, tool offsets, probing cycles, TCPs, and multi-axis machining

• Experience implementing CNC equipment or robotic manufacturing cells from requirements development through production qualification

• Knowledge of Lean Manufacturing, Six Sigma, PFMEA, control plans, SPC, and structured root-cause analysis

• Lean Manufacturing or Six Sigma certification

• A master's degree in Mechanical, Manufacturing, or Aerospace Engineering

INDH