Project Machinist

The Fabrication Engineering Group provides rapid fabrication, assembly, integration, and testing of advanced hardware prototypes for national security applications. Examples include the 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.

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 oftentimes requires leveraging several advanced manufacturing technologies in series to achieve the final deliverable part. This typically requires close collaboration with program engineers and other machinists to develop a holistic fabrication approach.

Internal fabrication resources are typically focused on supporting the most complex hardware, which oftentimes requires a collaborative to brainstorm the approach and determine which machines/technologies should be leveraged to provide the highest probability of success. Machinists typically have ownership of their assigned part's end to end fabrication lifecycle and provided substantial autonomy over developing their 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 with an enthusiasm, aptitude and willingness to learn new state-of-the-art technologies and software.

• ****Must have at least 10+ years of direct experience in simultaneous 5-axis machining, including setup, CAM programming, tooling selection, and CAM simulation
• Competency reading mechanical drawings and interpreting GD&T
• Ability to design and fabricate basic fixtures
• Demonstrated history mentoring and instructing junior machinists
• Experience using basic hand tools and inspection equipment, such as:
• Calipers, thread/pin gages, micrometers, dial indicator, etc...
• Previous experience with the following software types:
• CAM
• 3D CAD
• MS Office (Excel. Word, Outlook)
• Enthusiastic to learn new fabrication techniques, technologies, and machine tools
• Ability to work in a team environment and collaborate with other Laboratory personnel to solve fabrication challenges
• Comfortable attending manufacturability reviews with confidence to participate and provide feedback
• Self-motivator with excitement for working in R&D environment supporting novel prototype development that demonstrates technology of national importance
• Maintain a clean and well-organized work area and follow safety protocols
• Ability to lift up to 50lbs

• Previous work in high mix, low volume job shop environment
• Experience using the following:
• SolidWorks CAD software
• hyperMILL CAM software
• m&h on machine inspection software
• Heidenhain iTNC 530 controller
• Prior experience machining any of the following: Titanium, Invar, Metal Matrix Composites (MMCs), Hastelloy, 17-4 PH, Invar, Fiber Reinforced Composites
• Digital fabrication tools, such as;
• Model Based Definition (MBD)
• Product Lifecycle Management (PLM) software (Aras Innovator)
• Exposure to ultrasonic machining