Composites Machining Manufacturing Engineer II

Acara Solutions, Inc.; Bertram (TX); On-site; USD 95,000 - 114,000; Full time

Job summary

Acara Solutions, Inc. seeks a Composites Machining Manufacturing Engineer II in Bertram, TX to own machining processes from development to full-rate production. The role focuses on CFRP and composite structures, using Mastercam, Robotmaster, and KUKA robotic systems, with direct hire terms and a 40-hour workweek.

Ideal candidates bring 5+ years in aerospace manufacturing, expertise in CNC and robotic machining, and strong GD&T proficiency to ensure quality, cost, and schedule objectives are met.

Qualifications

• Bachelor’s degree in Mechanical/Manufacturing/Aerospace engineering or related field.
• 5+ years of experience in aerospace manufacturing with composite machining, CNC manufacturing, robotic machining, or advanced structures manufacturing.
• 5+ years developing or supporting CNC routing, trimming, drilling, milling, or other machining processes.
• 5+ years interpreting engineering drawings, CAD models, tolerances, and GD&T.
• 5+ years supporting manufacturing operations in production environments and collaborating with machinists, technicians, programmers, and operators.

Responsibilities

• Lead the development and implementation of machining processes for aerospace composite components (trimming, routing, drilling, milling, profiling, etc.).
• Develop and optimize machining strategies for CFRP, sandwich structures, honeycomb cores, and bonded assemblies.
• Develop CNC manufacturing processes including cutter selection, feeds and speeds, toolpath strategy, workholding, and inspection.
• Develop and optimize robotic machining processes including toolpath strategy, robot positioning, reach, and collision avoidance.
• Support production operation and optimization of KUKA robotic machining cells, including fixture setup and dimensional verification.
• Troubleshoot robotic machining issues involving Mastercam toolpaths, Robotmaster simulations, and KUKA motion.
• Collaborate with Design Engineering to improve manufacturability and design for machining.

Skills

Mastercam

Robotmaster

KUKA robotics

CNC routing

Robotic machining

GD&T

Composite machining

CFRP

Manufacturing engineering

Education

Bachelor's in Mechanical/Manufacturing/Aerospace

Master's in Mechanical/Manufacturing/Aerospace

Tools

Mastercam

Robotmaster

KUKA

Job description

Composites Machining Manufacturing Engineer II

Job Title: Composites Machining Manufacturing Engineer

Location: Bertram, TX

Employment Type: Direct Hire

Compensation: $95K - 114K/year.

Schedule: 40 hours/week

About the Opportunity

• We are seeking a highly motivated and dedicated Composite Machining Manufacturing Engineer to join our Structures Department.
• As part of a small, fast-paced, and passionate team, you will be instrumental in developing and scaling the manufacturing processes needed to produce advanced composite aerospace structures.
• You will be responsible for developing, implementing, and continuously improving machining processes for carbon fiber composite components, including CNC routing, trimming, drilling, profiling, and other secondary machining operations.
• You will own machining processes from initial development through full-rate production, develop tooling and workholding solutions, support CNC and robotic machining programming, and provide technical expertise to ensure parts meet demanding quality, cost, and schedule requirements.
• This role will support a manufacturing environment utilizing Mastercam for CNC programming, Mastercam and Robotmaster for robotic machining programming, and KUKA industrial robotic machining cells, in addition to conventional multi-axis CNC equipment.

Why You’ll Love Working Here

• Supportive, team-driven culture that values collaboration, transparency, and accountability.
• Opportunity to grow your career with a global workforce solutions leader serving multiple industries.
• People-first environment that encourages employees to bring their authentic selves to work.
• Strong focus on partnership, innovation, and delivering meaningful results for clients and candidates.

Why This Opportunity is Exciting

• This role offers the chance to join a company that prioritizes both people and performance-where your contributions directly impact client success while giving you room to grow and develop professionally.

What You’ll Do

• Lead the development and implementation of machining processes for aerospace composite components, including trimming, routing, drilling, milling, profiling, countersinking, and other secondary machining operations.
• Develop and optimize machining strategies for carbon fiber reinforced polymer (CFRP), sandwich structures, honeycomb core, foam core, bonded assemblies, and other composite configurations.
• Develop CNC manufacturing processes including cutter selection, feeds and speeds, toolpath strategy, workholding, datum strategy, probing, inspection, and process controls.
• Develop, review, simulate, prove out, and optimize CNC machining programs using Mastercam for multi-axis CNC equipment.
• Develop and optimize robotic machining processes including toolpath strategy, robot positioning, reach and accessibility, collision avoidance, spindle orientation, cutting parameters, approach/retract motions, and off-part movement.
• Support production operation and continuous improvement of KUKA robotic machining cells, including program prove-out, fixture setup, coordinate system establishment, tooling, machining parameters, dimensional verification, and troubleshooting.
• Develop machining strategies that account for the unique characteristics of robotic machining including robot stiffness, positional accuracy, repeatability, dynamic loading, tool orientation, reach limitations, singularities, and process-induced deflection.
• Develop robust part locating, fixturing, datum, and workholding strategies that maintain dimensional accuracy while preventing damage, distortion, or excessive loading of composite hardware.
• Optimize cutter selection, cutting parameters, and toolpath strategies to minimize delamination, fiber breakout, splintering, heat damage, surface damage, excessive tool wear, and other composite machining defects.
• Establish and continuously improve machining parameters including spindle speed, feed rate, depth of cut, cutter geometry, entry and exit strategy, drilling strategy, and tool-life requirements.
• Develop and implement tool-life management and cutter replacement strategies to maintain consistent machining quality and reduce manufacturing risk.
• Support implementation, qualification, and continuous improvement of CNC routers, machining centers, KUKA robotic machining systems, probing systems, vacuum workholding systems, and supporting production equipment.
• Evaluate machine and robot capability, accuracy, repeatability, and process capability to ensure equipment can meet engineering tolerances and production requirements.
• Troubleshoot robotic machining issues involving Mastercam toolpaths, Robotmaster simulation or output, KUKA robot motion, spindle orientation, work coordinate systems, fixture alignment, cutter engagement, vibration, dimensional variation, and robotic cell performance.
• Act as the manufacturing engineering subject matter expert and primary point of contact for composite machining operations and assigned hardware.
• Take ownership of machining hardware and production processes from development through full-rate production, ensuring adherence to safety, quality, cost, and schedule requirements.
• Provide hands‑on manufacturing floor support during machining operations, troubleshooting machine, robot, tooling, programming, workholding, and part-related issues.
• Develop detailed work instructions, setup documentation, machining procedures, tool lists, inspection requirements, and process specifications to standardize production operations.
• Interpret engineering drawings, GD&T requirements, CAD models, and inspection data to develop manufacturing processes capable of consistently meeting dimensional requirements.
• Collaborate closely with Design Engineering to improve design for manufacturability and design for machining, including tolerance strategy, datum structure, trim definitions, hole requirements, and tool accessibility.
• Lead the investigation and resolution of machining-related nonconformances through structured root cause analysis and implementation of effective corrective and preventive actions.
• Identify and resolve issues involving dimensional variation, machining defects, tool wear, fixture variation, machine performance, robotic performance, programming, and process instability.
• Establish and continuously improve robotic machining process capability, particularly for large composite trimming, drilling, routing, and milling operations.
• Identify opportunities for machining automation, probing, automated setup verification, in-process inspection, digital work instructions, and data‑driven process control.
• Support capital equipment selection and implementation, including development of technical requirements, equipment evaluation, acceptance testing, installation, qualification, and production readiness.

Job Requirements

What You’ll Bring

• Bachelor’s Degree in Mechanical Engineering or Manufacturing Engineering or Aerospace Engineering.
• 5+ years of experience in aerospace manufacturing along with composite machining, CNC manufacturing, robotic machining, or advanced structures manufacturing.
• 5+ years of experience developing or supporting CNC routing, trimming, drilling, milling, or other machining processes.
• 5+ years of experience interpreting engineering drawings, CAD models, tolerances, and GD&T.
• 5+ years of experience supporting manufacturing operations in a production environment and working directly with machinists, technicians, programmers, and production personnel.

What Sets You Apart

• Master's Degree in Mechanical or Manufacturing or Aerospace Engineering.
• 5+ years of experience in aerospace manufacturing, machining, manufacturing engineering, or a related engineering environment.
• Experience machining CFRP, fiberglass, honeycomb sandwich panels, Rohacell or other foam‑core structures, bonded composite assemblies, and large composite structures.
• Experience programming or supporting 3‑axis and 5‑axis CNC routers or machining centers.
• Hands‑on experience with Mastercam for multi‑axis CNC machining and toolpath development.
• Experience with Robotmaster for offline robot programming, simulation, collision detection, reach analysis, and robot code generation.
• Experience programming, proving out, or supporting KUKA industrial robotic machining systems.
• Experience developing machining workflows utilizing Mastercam, Robotmaster, KUKA robotic machining cells.
• Experience with robotic trimming, drilling, routing, and milling of large aerospace composite structures.
• Understanding of industrial robot kinematics and the differences between conventional CNC machining and robotic machining, including robot stiffness, accuracy, repeatability, reach, singularities, compliance, and dynamic response.
• Experience integrating KUKA robots with external machining spindles, tooling systems, workholding systems, and production equipment.
• Experience establishing and validating Tool Center Points (TCP), work coordinate systems, fixture coordinate systems, robot calibration, and part localization for robotic machining.
• Experience troubleshooting robotic machining programs involving tool orientation, reach, singularities, collision conditions, motion transitions, and machining‑induced deflection.
• Experience with CNC probing and automated part setup systems, including Renishaw or similar probing technologies.
• Experience developing vacuum fixtures, composite machining fixtures, drill fixtures, and large‑part workholding systems.
• Experience with machine tool and robotic cell accuracy, calibration, volumetric compensation, and process capability studies.
• Experience with automated tool setters, cutter‑life monitoring, and machining process automation.
• Experience with metrology and inspection systems including CMMs, laser trackers, portable measurement arms, or 3D inspection software.
• Understanding of machine‑code and robotic programming concepts including G‑code, cutter compensation, work coordinate systems, tool offsets, probing cycles, TCPs, and multi‑axis machining.
• Experience developing machining processes for large aerospace structures and tight‑tolerance composite components.
• Experience implementing new CNC equipment or robotic manufacturing cells from requirements development through production qualification.
• Experience with Lean Manufacturing, Six Sigma, PFMEA, control plans, SPC, and structured root‑cause analysis.
• Six Sigma or Lean Manufacturing certification.
• This position needs a strong background in aerospace manufacturing, composite machining, CNC and robotic machining equipment, practical problem solving, and the ability to quickly become an expert on complex hardware and manufacturing systems.
• Strong understanding of carbon fiber composite materials and the unique challenges associated with machining composite structures.
• Strong understanding of CNC machining principles, cutting tools, feeds and speeds, workholding, fixturing, machine setup, and manufacturing process development.
• Strong technical aptitude and ability to quickly become an expert on complex aerospace hardware and manufacturing equipment.
• Proficiency with CAD/CAM software for reviewing hardware and developing manufacturing processes, tooling, and fixturing.
• Demonstrated ability to troubleshoot complex manufacturing issues using structured problem‑solving and root‑cause‑analysis techniques.
• Excellent communication skills and ability to collaborate effectively with cross‑functional engineering and manufacturing teams.
• Demonstrated track record of driving process improvements and delivering measurable improvements in quality, cost, throughput, or schedule.
• High level of initiative, self‑motivation, and ability to thrive in a dynamic and fast‑paced aerospace manufacturing environment.
• Excellent analytical and problem‑solving abilities.

Additional Information

• Upon offer of employment, the individual will be subject to a background check and drug screen.

Aleron companies (Acara Solutions, Aleron Shared Resources, Broadleaf Results, Lume Strategies, TalentRise, Viaduct) are an Equal Opportunity Employer. Race/Color/Gender/Religion/National Origin/Disability/Veteran.

Applicants for this position must be legally authorized to work in the United States. This position does not meet the employment requirements for individuals with F-1 OPT STEM work authorization status.