Project Machinist

About the Group

The Fabrication Engineering Group provides rapid fabrication, assembly, integration, and testing of advanced hardware prototypes for national security applications. Examples include precision machining fiber mounts for airborne high-energy laser systems, multi-functional structures using additive processes for ground-based radar systems, custom printed circuit boards (PCBs) for space-borne data processing, and highly integrated mechanical packaging for undersea communication terminals.

Core mechanical competencies span precision fabrication, additive manufacturing, and 5-axis machining. The group concentrates on high-complexity parts, quick-turn capabilities, and activities that require concurrent engineering with program teams. Core PCB capabilities include design for manufacturability (DFM), automated solder paste dispensers, precise pick-n-place machines, and automated optical inspection systems. Assembly, integration, and test capabilities include integration spaces, clean rooms, vibration testing, thermal testing, and space simulation chambers. The Group focuses on state-of-the-art prototyping capabilities, technical excellence, exceptional collaboration, and outstanding operation.

About the Role

Given the nature of working in a high-precision environment, meticulous attention to detail is paramount in successful execution and delivery of high-quality hardware that’s instrumental to program success. The position supports high-precision mechanical fabrication (sub-thou accuracy typical) that often requires leveraging several advanced manufacturing technologies in series to achieve the final deliverable part. This typically involves close collaboration with program engineers and other machinists to develop a holistic fabrication approach.

Internal fabrication resources are focused on supporting the most complex hardware, which often requires collaborative brainstorming to determine the best machines and technologies for the highest probability of success. Machinists typically have ownership of their assigned part’s end-to-end fabrication lifecycle, including developing the fabrication approach, fixture design/fabrication, tooling, CAM programming, setup, and machine operation.

The ideal candidate is a talented, creative, and motivated individual with a strong aptitude for problem-solving, critical thinking, creativity, and excellent interpersonal, verbal/written communication, and time management skills. They should have an enthusiasm, aptitude, and willingness to learn new state-of-the-art technologies and software.

Responsibilities

• Perform simultaneous 5-axis machining, including setup, CAM programming, tooling selection, and CAM simulation.
• Read and interpret mechanical drawings and GD&T (Geometric Dimensioning and Tolerancing).
• Design and fabricate basic fixtures.
• Mentor and instruct junior machinists.
• Use basic hand tools and inspection equipment (calipers, thread/pin gages, micrometers, dial indicators, etc.).
• Collaborate with program engineers and other machinists to solve fabrication challenges.
• Participate in manufacturability reviews and provide feedback.
• Maintain a clean and well-organized work area while following safety protocols.
• Lift up to 50 lbs.

Requirements

• At least 10+ years of direct experience in simultaneous 5-axis machining.
• Competency in reading mechanical drawings and interpreting GD&T.
• Experience designing and fabricating basic fixtures.
• Demonstrated history of mentoring and instructing junior machinists.
• Experience using CAM, 3D CAD, and MS Office (Excel, Word, Outlook).
• Enthusiasm for learning new fabrication techniques, technologies, and machine tools.
• Ability to work in a team environment and collaborate with other personnel.
• Self-motivated with excitement for working in an R&D environment supporting novel prototype development.

Desired Skills

• Previous work in a high-mix, low-volume job shop environment.
• Experience using SolidWorks CAD software, hyperMILL CAM software, m&h on-machine inspection software, and Heidenhain iTNC 530 controller.
• Prior experience machining materials such as Titanium, Invar, Metal Matrix Composites (MMCs), Hastelloy, 17-4 PH, and Fiber Reinforced Composites.
• Familiarity with digital fabrication tools, including Model Based Definition (MBD) and Product Lifecycle Management (PLM) software (e.g., Aras Innovator).
• Exposure to ultrasonic machining.