Composites Machining Manufacturing Engineer II

ABOUT

Firefly Aerospace is a space and defense technology company on a mission to reliably and repeatedly launch, land, and operate space systems from Earth to the Moon and beyond. As the partner of choice for critical space missions, Firefly is the first commercial company to launch a satellite to orbit with 24-hour notice and the first company to achieve a successful Moon landing. Headquartered in north Austin, Texas, Firefly is looking for passionate, hardworking innovators to join our team and help fuel our successful trajectory into space.

SUMMARY

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 required 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.

This position requires 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.

RESPONSIBILITIES

• 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.

QUALIFICATIONS

Required

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Aerospace Engineering, or a related engineering field.
• Significant experience in aerospace manufacturing with demonstrated experience in composite machining, CNC manufacturing, robotic machining, or advanced structures manufacturing.
• Strong understanding of carbon fiber composite materials and the unique challenges associated with machining composite structures.
• Hands-on experience developing or supporting CNC routing, trimming, drilling, milling, or other machining processes.
• Strong understanding of CNC machining principles, cutting tools, feeds and speeds, workholding, fixturing, machine setup, and manufacturing process development.
• Experience interpreting engineering drawings, CAD models, tolerances, and GD&T.
• 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.
• Experience supporting manufacturing operations in a production environment and working directly with machinists, technicians, programmers, and production personnel.
• 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.

Desired

• 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.
• Master's degree in Mechanical, Manufacturing, or Aerospace Engineering is a plus.

Firefly offers outstanding benefits for our employees, including generous health, dental and vision plans with low plan deductibles, parental leave, educational/relocation reimbursement, short term disability, and flexible PTO options.

To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.

Firefly Aerospace, Inc. is an Equal Opportunity Employer; employment with Firefly is governed based on merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.