Applications Engineering Manager- Wire EDM

Job Summary: The Applications Engineering Manager - Wire EDM is a hands-on technical leader responsible for managing all Wire EDM applications engineering activities, with a primary focus on the FANUC Robocut product line. This role serves as the organization’s subject matter expert on wire electrical discharge machining processes, providing pre-sales and post-sales technical support, driving turnkey solution development, and leading a team of applications engineers. The ideal candidate brings deep expertise in FANUC Robocut machines, EDM process optimization, and customer-facing technical consultation., Technical Leadership

• Serve as the company’s foremost Wire EDM technical authority, with specific expertise in the FANUC Robocut a-C400, a-C600, and a-C800 platforms

• Develop and optimize cutting parameters, wire threading strategies, and machining processes across a range of materials (hardened tool steel, carbide, titanium, Inconel, etc.)

• Provide expert-level guidance on FANUC CNC controls, iHMI user interface, AWF3 automatic wire feeding, iPulse3 discharge control, Core Stitch slug retention, and AI-driven thermal compensation features

• Lead development of turnkey Wire EDM solutions including fixturing, programming, automation integration, and multi-axis (up to 7-axis) turn-and-burn applications

• Conduct test cuts, time studies, and machining demonstrations to validate process capabilities and support customer decision-making

Customer Engagement

• Partner with the sales organization to provide technical proposals, application feasibility assessments, and competitive positioning against Mitsubishi, Sodick, Makino, and other Wire EDM OEMs

• Conduct on-site and in-house customer training on Robocut machine operation, programming (G & M code), maintenance, and process optimization

• Serve as the technical escalation point for complex customer applications, troubleshooting, and process challenges

• Represent the company at trade shows, industry events, and technical seminars

Process & Strategy

• Develop and maintain a library of proven cut conditions, application notes, and technical documentation for internal and customer use

• Collaborate with FANUC engineering teams (domestic and Japan) on product feedback, beta testing, and new feature validation

• Track industry trends in Wire EDM technology, materials, and applications to identify new market opportunities across medical, aerospace, defense, energy, mold & die, and additive manufacturing sectors

• Contribute to continuous improvement initiatives and support ISO 9001 quality management objectives, * Recruit, develop, and manage a team of Wire EDM applications engineers, setting performance goals and conducting regular evaluations

• Establish training programs to ensure the team maintains current knowledge of FANUC Robocut technology, new product releases, and evolving EDM best practices

• Allocate engineering resources across pre-sales support, post-sales installation, customer training, and ongoing technical support activities

• Supervise geographically dispersed direct reports, ensuring operational efficiency and adherence to organizational policies.

• Deep, demonstrated knowledge of FANUC Robocut platforms, including CNC programming, power supply technology (SF3 / iPulse3), automatic wire feeding systems, and machine setup/optimization

• Expert understanding of wire EDM principles - discharge parameters, dielectric fluid management, wire tension control, surface finish optimization (to Ra 0.1 µm), taper cutting, and step/corner cutting techniques

• Proficiency in G & M code programming for Wire EDM, CAD/CAM software for EDM toolpath generation

• Thorough understanding of EDM behavior across conductive materials including hardened steels, carbides, titanium alloys, copper alloys, and superalloys

• Excellent verbal and written communication skills with the ability to translate complex technical concepts for customers, sales teams, and executive leadership

Minimum Education and Experience:

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, or related technical discipline - or equivalent combination of education and 10+ years of progressive Wire EDM experience

• Minimum 8 years of hands-on Wire EDM applications experience, including at least 3 years in a supervisory or team lead capacity

• Strong leadership and team management abilities

• Excellent communication skills across all organizational levels

• Design experience and development of programmed applications highly preferred.

• Prior experience with Fanuc controls is highly preferred.

• Prior experience with CAM-I is highly preferred; experience with Mastercam or Esprit a plus

• Prior experience in a machine tool distributor or OEM applications engineering environment

• Familiarity with FANUC CNC ecosystem (controls, servos, robotics) beyond Wire EDM

• Experience with automation integration for unattended Wire EDM operations (pallet systems, robotic loading)

• Knowledge of complementary machining processes (sinker EDM, CNC milling, grinding) and how Wire EDM fits within a broader manufacturing workflow

• Lean manufacturing or Six Sigma certification is a plus, * Willingness to travel up to 30% domestically, with occasional international travel

Physical Requirements:

• Ability to stand, walk, and work on the shop floor for extended periods

• Ability to lift up to 50 lbs