Manufacturing Engineer - Space and Defense

NO AGENCIES

Manufacturing Engineer

StarHagen Aerospace

Position Summary

StarHagen Aerospace is seeking a Manufacturing Engineer with strong CNC machining and programming experience to support the manufacture of complex, high-precision components for aerospace and defense applications.

The ideal candidate will have advanced Mastercam experience and a strong understanding of 3-, 4-, and 5-axis CNC machining, with particular emphasis on developing robust manufacturing processes for tight-tolerance, complex-geometry components.

This position is hands-on and production focused. The Manufacturing Engineer will be responsible for taking components from engineering definition through manufacturing process development, CNC programming, first article production, process validation, and sustained production.

Experience with metal additive manufacturing, particularly laser powder bed fusion (LPBF), is beneficial but secondary to strong CNC machining and process-engineering capabilities.

Primary Responsibilities

• Develop manufacturing processes for complex aerospace and defense components from engineering drawings, models, specifications, and customer requirements.
• Create, optimize, and maintain CNC programs using Mastercam, with a strong emphasis on complex 5-axis machining.
• Develop complete machining strategies including operation sequencing, workholding, tooling, cutting parameters, probing, in-process inspection, and final inspection requirements.
• Program and support precision milling operations involving complex geometries, tight positional tolerances, thin-wall features, difficult-to-machine materials, and challenging datum structures.
• Design and implement workholding, fixtures, soft jaws, locating systems, and other manufacturing aids.
• Select cutting tools and establish feeds, speeds, toolpaths, and machining parameters to maximize process capability, tool life, quality, and productivity.
• Provide hands-on support during setup, prove-out, first-piece machining, troubleshooting, and production.
• Identify and resolve machining problems including chatter, tool wear, distortion, tolerance drift, workholding issues, surface-finish problems, and process instability.
• Develop manufacturing plans and routers that clearly communicate production requirements to machinists, inspectors, and other manufacturing personnel.
• Support continuous improvement initiatives focused on cycle-time reduction, scrap reduction, process capability, throughput, and manufacturing cost.
• Work closely with Quality, Operations, Engineering, and Production personnel to resolve technical issues and ensure customer requirements are satisfied.
• Support First Article Inspection activities in accordance with AS9102.
• Ensure manufacturing processes comply with applicable aerospace and defense quality requirements, including AS9100, customer specifications, drawing requirements, configuration control, traceability, and controlled manufacturing processes.
• Support root-cause investigations and corrective actions related to manufacturing nonconformances.
• Review drawings, GD&T, models, specifications, and purchase-order requirements to identify manufacturing risks before production.
• Maintain CNC programs, setup documentation, manufacturing instructions, and other controlled production documentation.

CNC / Mastercam Requirements

The successful candidate should demonstrate substantial practical experience with:

• Mastercam
• 3-axis and 5-axis milling
• Simultaneous 5-axis machining
• Multi-operation precision machining
• CNC setup and prove-out
• Advanced workholding and fixturing
• Tool selection and cutting parameter development
• High-speed and dynamic machining strategies
• CNC probing and process verification
• Post processors and machine-specific programming considerations
• GD&T interpretation
• Tight-tolerance aerospace components
• Machining aluminum, stainless steels, titanium, nickel-based superalloys, and other aerospace materials

Candidates should understand machining beyond CAM programming alone. The position requires the ability to determine how a component should actually be manufactured, establish a repeatable process, and troubleshoot that process on the shop floor.

Aerospace & Defense Experience

Experience working within an aerospace, defense, or similarly controlled manufacturing environment is strongly preferred.

Knowledge or experience with the following is desirable:

• AS9100
• AS9102 First Article Inspection
• Aerospace drawing and specification requirements
• GD&T per ASME Y14.5
• Material and process traceability
• Special-process controls
• Configuration management
• Customer-specific quality requirements
• Nonconformance and corrective-action processes
• ITAR-controlled manufacturing environments
• Manufacturing documentation and revision control

Additive Manufacturing

Experience with metal additive manufacturing / Laser Powder Bed Fusion (LPBF) is a plus.

Relevant experience may include:

• Design and manufacturing considerations for LPBF components
• Build orientation and support strategies
• Additive manufacturing process limitations
• Machining of near-net-shape additive components
• Datum establishment and fixturing for printed components
• Support removal
• Heat treatment and stress relief
• Post-processing and surface finishing
• Dimensional inspection of additive components
• Integration of additive and subtractive manufacturing processes

Experience machining LPBF titanium, stainless steel, Inconel, or other aerospace alloys is particularly valuable.

Qualifications

• Degree in Manufacturing Engineering, Mechanical Engineering, Manufacturing Technology, or a related discipline preferred; equivalent hands-on manufacturing experience will be considered.
• Demonstrated experience developing CNC manufacturing processes.
• Strong proficiency with Mastercam.
• Demonstrated experience programming 5-axis CNC machining centers.
• Strong understanding of GD&T and engineering drawings.
• Experience manufacturing tight-tolerance precision components.
• Strong troubleshooting and root-cause-analysis capabilities.
• Ability to work directly with machinists, inspectors, engineers, and production personnel.
• Ability to independently take a component from drawing/model through a validated production process.

Preferred Qualifications

• Aerospace or defense manufacturing experience.
• Advanced simultaneous 5-axis Mastercam programming experience.
• Experience machining titanium, Inconel, stainless steel, and other difficult aerospace materials.
• Experience with automated manufacturing systems and probing.
• Fixture and workholding design experience.
• Experience supporting AS9102 First Article Inspections.
• Experience in an AS9100-certified manufacturing environment.
• Exposure to LPBF metal additive manufacturing.
• Experience developing machining and post-processing strategies specifically for additively manufactured components.

What We Are Looking For

This position is best suited for a manufacturing engineer who is equally comfortable programming in Mastercam, developing a machining process, and working at the machine during prove-out.

We are looking for someone who understands that producing complex aerospace hardware requires more than generating toolpaths. The successful candidate will understand the complete manufacturing process—from datum strategy and workholding through machining, inspection, documentation, and final production—and will be capable of developing processes that are repeatable, efficient, and capable of consistently meeting demanding aerospace and defense requirements.