Precision EDM (Sinker) Machinist

Purpose of the Role

The EDM Sinker Machinist is responsible for the setup and precision machining of intricate cavities and features into mold chases and inserts. This role focuses on maximizing the high-speed accuracy of Sodick machines and the intelligent power management of the AgieCharmilles FORM S350 to deliver flawless mold components. This role requires extreme attention to detail and the ability to work to tolerance as tight as ±0.005mm.

Key Responsibilities

• Sodick Operation: Program and operate Sodick Sinker machines (AG/AL series) using Linear Motor technology to ensure high-speed, vibration-free machining.

• Charmilles Operation: Manage the AgieCharmilles FORM S350, utilizing the AC Form HMI and iQ (Innovation + Quality) technology to minimize electrode wear.

• Mold Chase Fabrication: Precisely burn pocket geometries and shut-off features in large mold chases, ensuring perfect alignment with mating components.

• Electrode Management: Validate graphite and copper electrodes; utilize System 3R or Erowa tooling for high-repeatability setups.

• Process Optimization: Independently select and adjust generator settings (VDI finish, pulse duration, and jump speed) to meet strict surface integrity requirements.

• Autonomous Machining: Configure multi-electrode "burn sequences" for unattended or overnight machining runs.

• Quality Control: Conduct in-process inspections using micrometers, calipers, and CMM data to ensure all dimensions meet engineering specifications.

• Maintenance: Perform daily machine maintenance and ensure dielectric fluid levels and filtration systems are optimal.
  

Requirements & Qualifications

Technical Requirements

• Minimum of 3–5 years of experience specifically within high-precision mold chase fabrication or plastic injection mold making.

• Machine Mastery: Direct, hands-on experience with Sodick (AG/AL series) or GF AgieCharmilles (FORM series).

• Blueprints: Ability to read and interpret complex engineering drawings, including deep understanding of GD&T (Geometric Dimensioning and Tolerancing); ability to interpret 3D CAD files (STEP/IGES) to identify critical mold features.

• Precision Specs: Proven ability to consistently hold tolerances of ±0.005mm and achieve consistent surface finishes.

• Tooling Knowledge: Proficiency in using high-precision workholding systems (System 3R, Erowa) and on-machine probing for part centering.
  

Soft Skills & Education

Education: High School Diploma or equivalent; Technical degree or Apprenticeship in Tool & Die Making preferred.

Precision Mindset: A "quality first" approach with a track record of working on high-aesthetic or high-tolerance medical/automotive molds.

Detail Oriented: Meticulous in verifying electrode quality and cleanliness before starting a burn.

Problem Solving: Ability to troubleshoot surface finish issues or DC arcing during the burn process.