Sr. Manufacturing Engineer

Senior Manufacturing Engineer Position Summary: 

At Abrasive Form, we power and protect the planet. Abrasive Form is a world leader in high precision Industrial Gas Turbine (IGT) and Aerospace machining. We manufacture turbine blades and vanes for many of the largest gas turbine manufacturers and militaries in the world. We use high precision CNC milling, wire and sink electrical discharge machining (EDM), 3 axis creep feed and 5-axis CBN grinding.

The Senior Manufacturing Engineer reports directly to the Director of Engineering and will support new and existing product developments for complex machining processes and product launches. This hands-on role is responsible for developing and optimizing manufacturing processes, including EDM, CNC Milling, and Grinding, for high-performance turbine components. You will act as the primary engineering liaison with key customers, driving new product development, legacy product restarts, and process qualifications in a regulated manufacturing environment.

Key Responsibilities

• Lead process development for complex parts using 3 and 5 axis grinding, EDM and CNC milling.
• Act as technical point of contact for key customer(s), driving engineering communication and change requests.
• Manage product “restarts” for requalification of legacy parts including development of timelines and on-time execution.
• Define machining strategies (tool paths, fixtures, speeds/feeds, EDM burn parameters) to ensure quality, throughput, tool life and cost.
• Collaborate with cross-functional teams (Quality, Operations, Tooling, Vendors) to deliver robust engineered production solutions.
• Lead or participate in root cause investigations, CAPAs, and process improvements for yield and cycle time improvements, and scrap reduction.
• Mentor junior engineers as needed and support training of operators on new or revised processes.
• Utilize CAD/CAM systems (e.g., Mastercam, SolidWorks) to support programming and verification.
• Support customer audits, first article inspections (FAIs), and PPAP/FAI documentation as needed.

Required Qualifications

• Bachelor's degree in Mechanical Engineering or equivalent technical field.
• Minimum 5–10 years of hands-on experience in manufacturing engineering in regulated industries such as Gas Power, Aerospace, Aviation, Automotive, Medical Device, or similar.
• Expertise in:
  • CNC Milling Programming
  • Wire and Sink Electrical Discharge Machining (EDM) Programming
  • Creep Feed and/or CBN Grinding
• Experience with manufacturing documentation, process development, and NPI (New Product Introduction).
• Proficient in CAD/CAM software: Mastercam, SolidWorks, Vericut, etc.
• Ability to interpret complex engineering drawings, GD&T, and technical specifications.
• Strong written and verbal communication skills; customer-facing experience is essential.
• Familiarity with ISO, AS9100, or other aerospace/regulated manufacturing standards.

Preferred Qualifications

• Experience machining superalloys (e.g., Inconel, Hastelloy).
• Experience with legacy product restarts or reverse engineering.
• Prior experience with Haas controls is a plus.
• Six Sigma, Lean Manufacturing, or CI certification is desirable.
• Bilingual in English and Spanish is a plus.

Physical Demands & Work Environment

• Ability to work on the manufacturing floor with exposure to noise, temperature changes, and production equipment.
• Frequent standing, walking, bending, and lifting up to 25–50 lbs.
• Use of appropriate PPE and adherence to all safety protocols required.

Benefits Offered:

• Medical, Dental, and Vision Insurance
• Life Insurance
• Paid Time Off
• 401k Savings Plan
• $1,500 Sign On Bonus

Abrasive Form is an equal opportunity employer. All qualified applicants will receive consideration without regard to race, color, religion, sex, national origin, disability, protected veteran status, or any other characteristic protected by law. To comply with U.S. export control regulations, applicants must be eligible to receive any required authorizations from the U.S. Government.