Advanced Manufacturing engineer

Advanced Manufacturing Engineer – 5-Axis CNC & CAM Technologies
Location Athlone
Reports To Manufacturing Engineering Manager
Role Type - Full time onsite

Salary - €80,000 - up to €10k additional performance bonus, healthcare

About the Role
We are seeking an exceptional Advanced Manufacturing Engineer to join our growing Engineering team. This is a senior technical role responsible for developing world-class CNC machining processes for complex orthopaedic medical devices.
The successful candidate will be a recognised expert in simultaneous 5-axis machining, advanced CAM programming, machining process optimisation, and manufacturing technology. You will lead the development of highly efficient machining strategies using HyperMILL, implement advanced probing and automation routines, design innovative workholding solutions, and drive continuous improvements in productivity, quality, and process capability.
This is not a traditional CNC programming position. We are looking for a manufacturing technologist who understands machining science, advanced CAM strategies, fixture design, automation, and process engineering, and who is passionate about pushing the boundaries of advanced manufacturing.
Key Responsibilities
Advanced CAM Programming

• Develop, optimise, and validate complex simultaneous 5-axis CNC machining programs using HyperMILL.
• Develop machining strategies for complex free-form orthopaedic implant geometries with an emphasis on process capability, surface finish, tool life, and cycle time optimisation.
• Apply advanced machining strategies including:
  • Barrel Milling
  • Tangent Milling
  • High Efficiency Milling (HEM)
  • Adaptive Roughing
  • Dynamic Milling
  • Rest Machining
  • Tool Axis Optimisation
  • Automatic Feature Recognition
  • Collision Avoidance
  • Multi-axis finishing strategies
• Develop standardised CAM templates, machining libraries, post-processing methodologies, and programming standards.

CNC Process Development

• Develop robust machining processes from CAD model through to validated production.
• Optimise machining parameters including cutting tools, feeds, speeds, toolpaths, coolant strategies, and machine dynamics.
• Lead machine prove-outs and production process validation.
• Troubleshoot machining issues and implement sustainable corrective actions.
• Support New Product Introduction (NPI) and Design for Manufacture (DFM) activities.

Advanced CNC Programming & Automation

• Develop advanced probing routines using Renishaw Inspection Plus and machine-resident probing systems.
• Implement probing strategies for:
  • Automatic work offset setting
  • In-process dimensional verification
  • Adaptive machining
  • Tool breakage detection
  • Closed-loop manufacturing
• Develop CNC macro programs and parametric machining routines to automate repetitive programming tasks and improve manufacturing flexibility.
• Optimise machine automation to reduce setup times and improve machine utilisation.

Fixture & Workholding Design

• Design innovative machining fixtures and workholding systems using SolidWorks.
• Develop modular fixturing concepts to maximise machine utilisation and minimise setup time.
• Design robust location and clamping solutions suitable for complex simultaneous 5-axis machining.
• Collaborate with Manufacturing and Quality Engineering to validate fixture performance.

Continuous Improvement

• Drive machining innovation through the implementation of new tooling technologies, machining strategies, automation, and digital manufacturing techniques.
• Develop manufacturing standards and best practices across programming, tooling, fixturing, and machine setup.
• Mentor CNC programmers, manufacturing technicians, and engineers in advanced machining technologies.
• Support capital equipment selection, machine acceptance, and technology development projects.

Essential Requirements

• Degree in Mechanical, Manufacturing, Production Engineering or equivalent technical qualification such a trade of toolmaker with 8 to 10 years of extensive hands on experience.
• Minimum of 8 years' experience programming and developing simultaneous 5-axis CNC machining processes.
• Expert user of HyperMILL CAM software.
• Extensive experience programming complex simultaneous 5-axis machining centres.
• Proven expertise applying advanced machining strategies including Barrel Milling, Tangent Milling, Adaptive Roughing, High Efficiency Machining, and Dynamic Milling.
• Strong understanding of machining dynamics, cutter engagement, toolpath optimisation, and machining science.
• Extensive experience machining titanium, cobalt chrome, stainless steel, and other difficult-to-machine materials.
• Proven experience developing advanced Renishaw probing routines and machine-resident inspection strategies.
• Experience developing CNC macro programs and parametric machining solutions.
• Strong knowledge of Siemens, FANUC, and Heidenhain CNC controls.
• Experience designing machining fixtures and workholding systems using SolidWorks.
• Excellent understanding of GD&T and precision engineering principles.
• Proven ability to optimise machining processes for quality, productivity, and process capability.

Preferred Experience
Experience programming and supporting the following machine platforms is highly desirable:

• DMG MORI
• Makino
• Doosan

Experience with the following is also advantageous:

• Medical device or orthopaedic implant manufacturing
• ISO 13485 regulated manufacturing
• Validation (IQ/OQ/PQ)
• Digital manufacturing and CAM automation
• Multi-pallet or lights-out manufacturing systems
• Robotics and machine automation
• Tool management systems
• CAD/CAM integration
• Post processor development and optimisation

Personal Attributes
We are looking for an engineer who is:

• Passionate about advanced manufacturing technology.
• Curious, innovative, and driven to challenge conventional machining methods.
• A strong analytical thinker with excellent problem-solving skills.
• Highly organised and detail-oriented.
• Committed to engineering excellence and continuous improvement.
• Comfortable working independently while collaborating across multidisciplinary teams.
• A mentor who enjoys developing the technical capability of others.

Why Join Us?
This is an opportunity to join a rapidly growing orthopaedic medical device manufacturer committed to engineering excellence and advanced manufacturing technologies.
You will work with state-of-the-art CNC machining centres, advanced CAM software, and cutting-edge manufacturing technologies to produce life-changing medical devices. You will play a key role in shaping our future manufacturing capability through innovation, automation, and continuous improvement while helping develop the next generation of manufacturing engineers.
If you are passionate about advanced 5-axis machining, manufacturing innovation, and technical excellence, we would love to hear from you.

KSGalway

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