Senior Design Engineer - Injection Mold
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Overview
Job Description
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. This role will focus heavily on advanced 4‑ and 5‑axis machining, supporting design for manufacturability (DFM), inspection strategy development, and establishment of robust manufacturing methods across Chromalloy's global sites.
The ideal candidate brings deep hands-on experience with complex airfoil and tooling machining, strong proficiency in NX CAD/CAM modeling, and the ability to bridge design intent, machining strategy, and inspection planning. Familiarity with gas turbine operation and airfoil coating systems is preferred to enable informed decisions across the full component lifecycle.
What You'll DoDesign & Manufacturability
Lead DFM for 4- and 5-axis airfoil machining, influencing geometry, tolerances, and datum strategies for stable, repeatable productionIdentify 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 methodsServe 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 inspectionSupport 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 intentSupport 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 sitesMentor junior engineers in DFM, NX modeling, and manufacturing fundamentals
What You Bring
Bachelors in Mechanical, Aerospace, or Manufacturing Engineering8+ 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 materialsDeep hands-on experience in 4- and 5-axis machining of complex airfoil geometry and tight-tolerance surfacesStrong GD&T, datum selection, and tolerance stack-up knowledge applied to complex hardwareExperience with machining-aligned inspection planning and CMM or optical measurement
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