Senior Machining Process Engineer – RD

Responsibilities

• Process Characterization, Metrology & Quality
• Metrology, surface finish, and inspection methods
• Establish SPC and capability baselines and drive loss/defect rates down with data
• Equipment Specification & New Process Introduction (NPI)
• Evaluate, specify, and justify new machining and finishing processes to Vulcan; run vendor trials, define acceptance criteria.
• Document developed processes and hand off validated, capable processes to pilot production — including processes destined for future high-volume magnet factory programs.
• Optimization of Existing Machining Processes
• Develop and optimize slicing, grinding, abrasive, tumbling processes
• Minimize loss and maximize material yield while holding thickness tolerance, TTV, bow, and warp targets; quantify the yield-vs-throughput trade space for varying magnet geometries.
• Development of novel tooling and fixturing as needed
• Understand and quantify surface effects on downstream coating adhesion, corrosion, and magnetic performance.
• Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business
• We are looking for depth in abrasive machining plus the range to own everything around it:
• Abrasive Machining of Hard/Brittle Materials: Direct experience machining sintered magnets, technical ceramics, carbide, glass, silicon/semiconductor wafers, or similar brittle materials.
• Diamond Tooling: Working knowledge of diamond wire, wheel, and media specification.
• Machine Craft: Comfortable at the machine: setup, alignment, fixturing, troubleshooting vibration and chatter.
• Coolant & Filtration Systems: Practical understanding of coolant chemistry, delivery, filtration technologies, and swarf/sludge handling.
• Statistics & DOE: Fluency in designed experiments, measurement system analysis, SPC, and capability studies.
• Metrology & GD&T: Strong command of GD&T interpretation and precision dimensional/surface metrology at micron scale.
• CAD & Fixture Design: Able to design and iterate workholding, carriers, and handling fixtures (SolidWorks, Fusion 360, or similar).