Senior Design Engineer - Injection Mold

About the role

The Senior Manufacturing Engineer will be a key technical contributor within the Advanced Manufacturing Team, with primary responsibility for enabling machining-centric manufacturability of turbine airfoils and related manufacturing tooling (injection molds, machining fixtures, inspection fixtures, etc.) from early design through production deployment.

Responsibilities

• Design & Manufacturability Lead DFM for 4- and 5-axis airfoil machining, influencing geometry, tolerances, and datum strategies for stable, repeatable production
• Identify machining-driven NPI risk early and support toolpath and strategy development with site teams
• NX Modeling & Manufacturing Models Build manufacturing-friendly models (split lines, stock, feature definitions) and evaluate turbine tooling designs using advanced manufacturing methods
• Serve as NX subject matter expert across manufacturing and inspection applications
• Inspection Strategy Define inspection strategies in lockstep with manufacturing; develop datum schemes supporting both machining stability and downstream inspection
• Support CMM programming, scan strategies, FAI planning, and partner with Quality and Metrology on cost and cycle time
• Site Coordination & Method Development Partner with global sites to establish methods, validate process capability, and transfer machining and inspection intent
• Support troubleshooting through launch and ramp-up; guide process qualification and method approval
• Technical Leadership Drive structured problem-solving to improve yield, cycle time, and process robustness across programs and sites
• Mentor junior engineers in DFM, NX modeling, and manufacturing fundamentals

Requirements

• Bachelor's in Mechanical, Aerospace, or Manufacturing Engineering
• 8+ years of experience in aerospace or industrial gas turbine manufacturing, with a strong portion in airfoil machining and/or tool and die manufacturing
• Proficiency with Siemens NX and ability to read CAD drawings or assemblies
• Understanding of mold manufacturing processes including CNC machining, wire EDM, and grinding
• Experience with injection molding processes and materials
• Deep hands-on experience in 4- and 5-axis machining of complex airfoil geometry and tight-tolerance surfaces
• Strong GD&T, datum selection, and tolerance stack-up knowledge applied to complex hardware

Qualifications

• Familiarity with gas turbine operation and airfoil coating systems is preferred to enable informed decisions across the full component lifecycle

Skills

• Advanced 4- and 5-axis machining
• Strong proficiency in NX CAD/CAM modeling
• Ability to bridge design intent, machining strategy, and inspection planning

Benefits

• Comprehensive and flexible benefit options starting on day one, including medical, dental, vision, EAP, wellness incentives, and 401(k) with employer matching
• Development & progression opportunities for every employee – regular performance conversations, training and development curriculum, and engineering fellowship programs
• Paid time off, including vacation, sick time, paid holidays, and parental leave—all eligible on your first day of employment!
• Competitive pay, including eligibility for quarterly and annual bonuses, depending on role and site

Pay

The salary range for this position reflects a broad spectrum of experience levels. Individual compensation within the range is determined by multiple factors, including relevant experience, education, certifications, job related skills, internal equity, and market conditions. We evaluate each candidate individually to ensure fair and competitive pay decisions.

Schedule

Due to government regulation only US persons (U.S. citizen, U.S. naturalized citizen, U.S. permanent resident, holder of U.S. approved political asylee or refugee status) may be considered for this role.

Company Information

• Chromalloy is a global engineering & solutions company.
• We are a leading provider of aftermarket parts, repairs, and solutions that safely & reliably extend the life of aircraft engines and gas turbines.
• We develop, manufacture and repair critical turbine components for a range of engine platforms.
• Our solutions support the engines running the aerospace, energy and defense industries around the world.