EDM Programmer (Starlink)

About the role

This position supports the mass production of Starlink hardware by managing sinker and wire EDM operations. You will focus on creating complex molds and die sets to ensure high-scale manufacturing output. In this capacity, you own the end-to-end execution of EDM programming for critical manufacturing components. You are responsible for ensuring that all electrode designs translate into precise and repeatable machining programs. The role requires you to act as a bridge between engineering design and shop floor execution. You will collaborate directly with engineers to optimize geometry for manufacturability and efficiency. Ownership of process validation and ensuring parts meet strict tolerance requirements is central to this position. You contribute directly to the scalability and reliability of Starlink hardware production.

Key facts

What you'll do

• Program, set up, and operate sinker and wire EDM equipment to execute complex part requirements.
• Design and pull electrodes in collaboration with engineers to optimize their geometry for efficient and accurate machining.
• Program and operate graphite CNC machines to machine intricate components with high precision.
• Machine electrodes to meet precise tolerance requirements while adhering to demanding production deadlines.
• Refine machining parameters for various materials and surface finishes to improve tool life and part quality.
• Build custom fixtures for the EDM department to enhance workholding stability and reduce setup times.
• Conduct preventative maintenance on machinery to ensure optimal performance and minimize unplanned downtime.
• Perform secondary machining tasks and inspect parts using micrometers, gauges, and indicators to verify dimensional accuracy.
• Maintain detailed documentation of processes, adjustments, and quality checks for traceability and continuous improvement.
• Support the development of standard operating procedures for EDM operations to ensure consistency across shifts.
• Troubleshoot machining issues by analyzing program code, tooling, and material behavior to resolve defects efficiently.
• Contribute to process improvement initiatives aimed at increasing throughput and reducing scrap rates in the manufacturing workflow.

Requirements

• High school diploma or equivalent is mandatory for this position.
• 3+ years of experience programming sinker EDM machines is required for technical proficiency.
• 1+ year of experience with CNC programming for electrodes is necessary to ensure accurate electrode fabrication.
• 1+ year of experience designing or pulling electrodes is essential for fulfilling core job responsibilities.
• Ability to lift 25 lbs unassisted is required to perform physical tasks safely in the manufacturing environment.
• Physical ability to stand, bend, and climb for extended periods is necessary to complete assigned duties.
• Availability for 1st shift (6:00 am to 4:30 pm) or 2nd shift (3:30 pm to 2:00 am) is mandatory to maintain operational continuity.
• Willingness to work overtime and weekends as needed to meet production schedules and urgent demands.
• Compliance with ITAR regulations requires U.S. citizenship, permanent residency, refugee, or asylee status.
• Successful completion of background checks and authorization to work in the United States is required for employment.

Nice to have

• 5+ years of experience in CNC EDM setup, operation, and programming is preferred for advanced problem-solving.
• 5+ years of experience with GF+ wire machines is valued for specialized wire EDM expertise.
• Proficiency in reading blueprints and applying GD&T ensures accurate interpretation of engineering specifications.
• Experience with CNC EDM hole drilling or hole popper setup is preferred for expanded machine versatility.
• Expertise in EDM work holding, including System 3R and robotics, is valued for improving fixture efficiency.
• Deep understanding of cutting parameters for graphite and copper is preferred to optimize machining performance.

Skills & tools

• Sinker EDM
• Wire EDM
• Graphite CNC
• Electrode design
• GD&T
• System 3R work holding
• GF+ wire machines

Practical notes

This position is subject to ITAR regulations, requiring applicants to be U.S. citizens, permanent residents, refugees, or asylees.

2nd shift employees must be available for 1st shift onboarding and periodic meetings.