ods Engineer Metallics Machining

About Skyroot Aerospace

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An Aerospace Metallics Machining Methods Engineer specializes in the development optimization and management of machining processes for metallic components used in aerospace applications. This role involves ensuring that metallic parts (e.g. aluminum titanium steel nickel alloys) are manufactured to high precision meeting the stringent performance quality and safety requirements of the aerospace industry. The engineer works closely with design manufacturing and quality teams to ensure costeffective and reliable production.

1. Process Design and Development

• Develop and optimize machining processes for aerospace metallic components focusing on materials such as aluminum titanium stainless steel and superalloys (e.g. Inconel).
  
• Collaborate with design engineers to review product designs for manufacturability ensuring that components can be efficiently and accurately machined.
  
• Create and simulate CNC machining programs (using CAD/CAM software such as CATIA Siemens NX ESPRIT or Mastercam) to manufacture complex aerospace components.
  
• Develop detailed process documentation including machining sequences tool selection cutting parameters and work instructions.
  

2. Tooling and Equipment Optimization

• Select and design appropriate cutting tools jigs fixtures and work holding devices to optimize machining processes.
  
• Work closely with tool suppliers to ensure the selection of tools that maximize efficiency tool life and precision.
  
• Evaluate the performance of CNC machines (e.g. lathes mills multiaxis machines) and optimize machine settings to achieve the best balance of speed accuracy and tool life.
  
• Investigate and recommend new machining technologies (e.g. highspeed machining adaptive machining and robotic systems) to improve productivity and quality.
  

3. Process Optimization and Continuous Improvement

• Analyze existing machining processes to identify inefficiencies bottlenecks and opportunities for improvement.
  
• Implement lean manufacturing principles such as Six Sigma and Kaizen to reduce waste improve cycle times and increase overall process efficiency.
  
• Conduct root cause analysis on machining defects such as surface finish issues dimensional inaccuracies or tool wear and implement corrective actions.
  
• Continuously monitor and adjust machining parameters to ensure that the production process remains costeffective reliable and capable of meeting tight aerospace tolerances.
  

4. Quality Control and Assurance

• Collaborate with quality assurance teams to ensure that all machined parts meet aerospace industry standards (e.g. AS9100) and customer specifications.
  
• Develop inspection protocols and inprocess checks including firstarticle inspection (FAI) and statistical process control (SPC) to monitor machining accuracy.
  
• Ensure that all machining processes comply with aerospace quality standards and regulatory requirements.
  
• Address nonconformities by conducting failure analysis and implementing process improvements.
  

5. Material and Machining Expertise

• Develop expertise in the machining of aerospacegrade metallic materials such as aluminum alloys titanium alloys stainless steels and superalloys.
  
• Optimize cutting speeds feed rates and cooling/lubrication methods for each material to ensure optimal surface finishes dimensional accuracy and tool life.
  
• Troubleshoot challenges associated with difficulttomachine materials such as titanium and nickelbased alloys ensuring minimal tool wear and highquality finishes.
  

6. Project Management and Collaboration

• Lead machining process development projects from initial concept through to fullscale production ensuring that projects are completed on time and within budget.
  
• Work closely with crossfunctional teams including design manufacturing quality and procurement to ensure alignment on project goals.
  
• Prepare and present technical reports and process updates to internal and external stakeholders including customers and management.
  
• Coordinate with suppliers and vendors for equipment procurement tooling design and material selection.
  

7. Compliance and Safety

• Ensure that all machining processes comply with aerospace industry standards including AS9100 NADCAP.
  
• Develop and implement safety protocols and guidelines for machining processes including the handling of hazardous materials (e.g. coolant metal dust).
  
• Ensure compliance with environmental regulations related to waste management coolant disposal and energy consumption.
  
• Promote a safe working environment by conducting risk assessments and implementing safety measures for CNC machine operators and staff.
  

8. Research and Development

• Stay updated on the latest advancements in machining technologies and materials relevant to aerospace manufacturing.
  
• Explore and implement innovative machining techniques such as 5axis machining automated inspection systems and digital twin technology.
  
• Research new materials and machining strategies to support the development of nextgeneration aerospace components that are lighter stronger and more fuelefficient.
  

• Machining Expertise: Strong knowledge of CNC programming milling turning grinding and drilling processes particularly for aerospace applications.
  
• Material Knowledge: Indepth understanding of machining aerospacegrade metals (aluminum titanium Inconel stainless steel).
  
• CAD/CAM Proficiency: Skilled in CAD/CAM software for designing and programming machining processes (e.g. CATIA Siemens NX Mastercam& ESPRIT).
  
• Quality Control: Knowledge of aerospace quality standards (AS9100 NADCAP) and experience with SPC FAI and other quality assurance tools.
  
• ProblemSolving: Strong analytical and troubleshooting skills for addressing machining issues and optimizing processes.
  
• Project Management: Ability to lead and manage complex machining projects coordinating with crossfunctional teams and external suppliers.
  

Educational Qualifications:

Certifications (Optional but beneficial):

• CNC Programming Certification
  
• Six Sigma Green/Black Belt certification for process optimization.
  
• Lean Manufacturing certifications or equivalent.