Associate Principal Engineer

Job Description SummaryThis key position within the manufacturing engineering group will research dental and medical industry trends and precision machining technologies to challenge current processes and drive continuous improvement. The Associate Principal Engineer will use past experience and new learnings to deliver mid-level projects with minimal supervision, with a primary focus on CNC machining processes, programming, tooling, and automation. Responsible for improving current processes, increasing machine efficiencies, and developing best practices for New Product Introductions (NPI). This role will be responsible for developing key relationships with other functions at the site and external manufacturing partners. The Associate Principal Engineer will effectively manage projects and coach and mentor junior engineers, CNC programmers, and machinists.Key ResponsibilitiesGeneralLead multidisciplinary technical teams and provide key engineering functions across multiple functional groups within the sitePresent finished projects to site leadershipManage mid-scale projectsDevelop expertise in precision machining for the dental and medical device industriesWork with external companies/organizations (machine tool builders, cutting tool suppliers, CAM software vendors) on technology development while maintaining project timelines and ensuring efficient use of resourcesTake an active role in site-level decisions and initiativesProvide coaching/mentorship to other engineers, CNC programmers, and machinistsProcessProcess ownership for CNC machining and assembly operations. Full-scale leadership on machining and production projects across the siteRecommend and implement machining process improvements (cycle time, tool life, scrap reduction, OEE) based on key performance indicators (KPIs)Lead reviews of machining process design for compliance with engineering principles, company standards, customer contract requirements, and related specificationsDevelop alternative machining processes, cutting tools, workholding, and materials to improve cost and efficiency while preserving product quality and outputOptimize cutting parameters (speeds, feeds, depth of cut, coolant strategy) for medical-grade materials including stainless steels, titanium, NiTi, carbides.Design and execute new process qualifications (IQ/OQ/PQ) for new machining platforms and base technologies across multiple manufacturing platformsReview and assess the production "package" including CNC programs, setup sheets, tool lists, work instructions, travelers, drawings, and labelingSelect machine tools, cutting tools, workholding, and metrology equipment based on analysis of specifications, capability studies, reliability, and regulatory requirementsResearch future machining technologies (multi-axis milling, Swiss-type turning, turn-mill, micro-machining, hard turning, grinding) and develop test methods that are accurate, time-efficient, and cost-effectiveAttend technical conferences and trade shows (e.g., IMTS, EMO) to identify new opportunities in machine tools, tooling, workholding, metrology, and automationLead initiatives for the development, introduction, improvement, and sustainment of machining processes, including Lean manufacturing techniques, SMED/setup reduction, and a philosophy of continuous improvementDesign/DevelopmentApply Design for Manufacturability (DFM) principles to machined components, working with design engineering to optimize part geometry, tolerancing, and material selection for CNC productionUse current engineering best practices in the design, development, testing, documentation, and manufacturing of products with adherence to industry & GMP standardsManage design history file (DHF) including design review meetings, phase sign-offs, and ensure seamless transition to manufacturingDevelop and maintain the design control process (DMR, DHF, Technical Files, etc.)Create fixture, workholding, and gauge designs with supporting documentation; produce design models, drawing details, assembly drawings, and associated engineering documentation with 3-D parametric modeling software, MS Word, Excel, and PowerPointIdeate and lead continuous improvement initiatives focused on current product performance and manufacturing costsDirect final product verification and validation, including first article inspection (FAI) and process capability studies (Cpk/Ppk)Maintain all documentation for existing products; keep current work instructions, travelers, drawings, and labeling based on knowledge of changing regulatory requirementsManage the new product introduction (NPI) process from conceptualization through introduction to manufacturing, ensuring machinability and capable processes are established at launchLiaise with customers and commercial teams to define NPI requirements and ensure NPI activities fulfill requirementsDevelop test and inspection methods for new products and use data to iterate on product and process designsResearch new material characterization, cleaning validation, metrology, and inspection techniques relevant to machined medical componentsEnsure compliance in all aspects of Environmental, Health and Safety per industry standards and local regulationsCNC Machining & ProgrammingServe as the site's technical authority for CNC machining: multi-axis milling (3/4/5-axis), Swiss-type turning, turn-mill, and grinding platformsDevelop, prove out, debug, and optimize CNC programs using CAM software (e.g., Mastercam, Esprit, GibbsCAM) and direct G-code/M-code editing; manage post-processors and program revision controlLead new machine tool selection, justification, installation, and qualification, from URS through IQ/OQ/PQDesign and implement workholding, fixturing, and automation solutions (bar feeders, robotic load/unload, pallet systems) to improve throughput and reduce operator dependencyEstablish and maintain tool management practices: tool selection, presetting, wear monitoring, tool life tracking, and standardized tooling librariesTroubleshoot machining issues including chatter, tool wear, thermal drift, burr formation, and surface finish defects; perform root cause analysis and implement corrective actionsDefine and validate in-process and final inspection strategies (CMM, vision systems, optical comparators, surface finish measurement) for tight-tolerance medical componentsIntegrate machine tools with shop-floor systems (machine monitoring, DNC, MES/ERP) to enable data-driven process controlEnsure preventive maintenance programs for machining equipment are current and effectiveGenerate accurate and controlled documentation pertaining to CNC equipment, programs, setups, and processesResearch the latest machining technologies (micro-machining, adaptive toolpaths, hybrid additive/subtractive, in-machine probing) and implement where they add valueSpecific Knowledge & SkillsBachelor's or Master's Degree in Engineering (Mechanical, Manufacturing, Industrial, or related discipline)Demonstrated expertise in CNC programming and machining processes; hands-on proficiency with CAM software and G-code/M-codeStrong knowledge of cutting tool technology, machinability of medical alloys (stainless steel, titanium, NiTi, carbide), workholding, and fixture designAbility to define documents such as operating and maintenance instructions, technical drawings, industrial standards, and procedure manualsAbility to write technical reports and technical correspondence with management; ability to review and critique junior engineers' reportsDetail-oriented, with ability to organize, document, and communicate across the organization5+ years of medical or dental device manufacturing experience, with significant time in a precision machining environmentKnowledge of regulatory requirements (FDA QMSR, ISO 13485, and others) an advantage.High level of proficiency in GMP quality standardsExperience executing Six Sigma and Lean Manufacturing projects, including deployment and training of these concepts (SMED, SPC, DOE) an advantageProficient in new product development processes from concept through full production releaseExperience leading large-scale projects in a manufacturing environment, with the ability to manage project cost within a defined budgetExperience in research projects and process/product conceptualizationGeneral Skills & CompetenciesExcellent understanding of industry practicesStrong proficiency with tools, systems, and proceduresStrong planning/organizational skills and techniquesStrong decision-making, analysis, and problem-solving skills with ability to multi-taskExcellent verbal and written communication skillsStrong presentation and public speaking skillsStrong interpersonal skillsStrong conflict resolution skills and ability to deliver difficult messagesAbility to build partnerships at all levels within the company and externallyStrong negotiation skillsAbility to resolve complex issues effectively.Project management, consultative skills, and ability to manage a budgetMinimum Work ExperienceTypically 6 to 8 or more years of increasing responsibility in terms of any applicable professional experience, with substantial experience in CNC machining environments.Preferred EducationTypically a Bachelor's Degree or global equivalent in a related discipline. Master's degree or global equivalent a plus. May hold one or more industry certifications (e.g., NIMS, journeyman machinist, Mastercam/Esprit certification, Six Sigma).Travel / Physical DemandsTravel typically less than 10%. Office and manufacturing floor environment. No special physical demands required.