Fabrication Engineer

Job Description

Job Description

Position Summary

The Fabrication Engineer is responsible for supporting and improving manufacturing processes related to sheet metal fabrication, forming, machining, and assembly operations. This position requires a strong hands-on manufacturing background with expertise in material behavior, tooling design, CNC programming, forming techniques, and troubleshooting complex fabricated components. The Fabrication Engineer will work closely with Engineering, Production, Quality, and Tooling departments to develop efficient manufacturing methods and resolve production challenges.

Essential Duties and Responsibilities

Manufacturing Engineering

• Develop, improve, and maintain manufacturing processes for fabricated sheet metal components.
• Provide technical support to fabrication, forming, machining, and assembly operations.
• Review engineering drawings, specifications, and customer requirements to ensure manufacturability.
• Analyze production processes and implement improvements to increase quality, productivity, and efficiency.
• Support new product introduction and production launch activities.

Sheet Metal Forming & Material Expertise

• Possess extensive knowledge of sheet metal materials, grain direction, bend allowances, springback, forming limitations, and material behavior during fabrication.
• Determine proper forming methods based on material type, thickness, and part geometry.
• Evaluate and troubleshoot forming issues including cracking, splitting, distortion, wrinkling, and dimensional variation.
• Recommend process improvements and tooling modifications to improve part quality and manufacturability.

Tooling Design & Development

• Design and develop:
• Forming dies
• Joggle tooling
• Form blocks
• Press brake tooling
• Fixtures and manufacturing aids
• Collaborate with toolmakers and production personnel to ensure tooling effectiveness and longevity.
• Validate tooling designs through testing and production trials.

CNC Programming & CAD/CAM

• Create and maintain DXF files for manufacturing equipment.
• Program and optimize CNC Routers for production operations.
• Develop CNC programs for complex fabricated components.
• Generate machine-ready files for Waterjet and CNC Router equipment.
• Support setup and troubleshooting of CNC manufacturing processes.

Press Brake Programming

• Develop and optimize press brake programs for complex and multi-stage bends.
• Determine proper bend sequences, tooling selection, and setup requirements.
• Verify bend calculations and material allowances to achieve dimensional accuracy.
• Assist operators with programming and troubleshooting challenging formed components.

Troubleshooting & Process Improvement

• Investigate and resolve manufacturing issues involving:
• Cracking materials
• Improper forming
• Die-related defects
• Dimensional inaccuracies
• Equipment setup issues
• Conduct root cause analysis and implement corrective actions.
• Work with Quality and Production teams to reduce scrap and improve process capability.

Technical Documentation

• Interpret and work from engineering drawings, blueprints, customer specifications, and manufacturing standards.
• Read and utilize Mylar drawings, digitized overlays, and TIF file formats.
• Create and revise manufacturing documentation, setup instructions, and process sheets.
• Maintain engineering records and program revisions.

Required Qualifications

Education

• Bachelor's Degree in Manufacturing Engineering, Mechanical Engineering, Industrial Engineering, Engineering Technology, or equivalent experience preferred.
• Equivalent combination of education, technical training, and manufacturing experience may be considered.

Experience

• Minimum 5 years of manufacturing engineering experience in a sheet metal fabrication environment.
• Experience with forming operations, tooling design, CNC programming, and fabrication processes.
• Hands-on experience troubleshooting complex fabricated and formed components.

Required Knowledge and Skills

• Strong understanding of sheet metal fabrication and forming processes.
• Knowledge of material characteristics and forming behavior.
• Experience designing dies, joggle tooling, form blocks, and fixtures.
• Advanced knowledge of press brake programming and setup.
• Experience creating and modifying DXF files.
• Experience programming CNC Routers and supporting Waterjet operations.
• Ability to troubleshoot complex forming and manufacturing issues.
• Knowledge of Mylar drawings, legacy manufacturing prints, and TIF file formats.
• Proficiency with CAD/CAM software.
• Strong blueprint reading and GD&T interpretation skills.
• Root cause analysis and problem-solving abilities.
• Excellent communication and cross-functional collaboration skills.

Physical and Environmental Requirements

• Ability to work in both office and manufacturing environments.
• Ability to stand, walk, and move throughout the production floor for extended periods.
• Ability to occasionally lift up to 25 pounds.
• Ability to safely work around manufacturing equipment, machinery, and tooling.
• Use of required personal protective equipment (PPE) when in production areas.

Preferred Qualifications

• Aerospace, defense, or precision sheet metal manufacturing experience.
• Experience with complex formed sheet metal components.
• Experience with ERP/MRP systems.
• Knowledge of lean manufacturing and continuous improvement methodologies.
• Experience supporting AS9100 or ISO 9001 quality systems.

Work Environment

This position is based in a manufacturing environment that includes sheet metal fabrication, machining, and production operations. Employees may be exposed to noise, airborne particles, dust, chemicals, and solvents associated with manufacturing processes.

Depending on job duties and work location, the use of personal protective equipment (PPE), including respiratory protection and hearing protection, may be required. Safety glasses are mandatory at all times while in production areas.

Employees must be able to safely work around manufacturing equipment, powered machinery, and material handling devices. The company maintains a strong commitment to workplace safety and complies with all applicable OSHA regulations and safety standards.