Composites Machining Manufacturing Engineer II

Job description

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 thr