Process Engineer (CNC Innovation)

PROCESS ENGINEER (CNC INNOVATION) Freeform builds AI-native manufacturing systems that unify software, hardware, and physics to produce industrial-scale parts at the speed of human ideation. By treating manufacturing as a single integrated system, we unlock a new era of innovation where complex hardware is designed, built, and scaled without limits. As a Process Engineer (CNC Innovation) at Freeform, you will have the unique opportunity to bridge the gap between fundamental machining physics and next-generation autonomous manufacturing. You will deep dive into the complex, multi-physics phenomena of metal cutting, specifically the mechanics of toolpath generation and plastic deformation to gain a fundamental understanding of the process with the ultimate goal of enabling Freeform to develop its own proprietary subtractive manufacturing technology. You will work alongside an interdisciplinary team of software and controls engineers to translate domain expertise into automated toolpath logic and closed-loop control systems. Ultimately, your work will contribute to Freeform’s vision of unifying the entire metal manufacturing ecosystem from autonomous 3D printing to autonomous subtractive manufacturing and post-processing. The ideal candidate possesses the academic rigor to investigate and model the mechanics and physics behind processes yet is grounded in the practical challenges of machining hard metals. 3D printing experience is not required to be successful here - we look for leaders who are organized, accountable, collaborative, and motivated to build and scale world-class hardware operations. Responsibilities: Develop a deep understanding of the physics of the machining process, focusing on plastic deformation under various cutting conditions and toolpath optimization Work independently to design and execute machining experiments on hard metals, analyzing data to develop and optimize automated CAM processes Act as the primary domain expert for CNC/CAM automation, providing the mechanical and physical insights necessary for the software team to write automation code Perform sample cuts and process development on-machine, ensuring a clean and actionable data stream to monitor the performance of those cuts Develop and implement novel toolpath strategies and force modeling to extend tool life and improve surface finish Collaborate with software and controls engineers to implement Closed Loop Control (CLC) systems that move beyond static feeds and speeds Strategize continuous improvement plans for CNC process development, focusing on scalability from prototype to high-volume production Basic Qualifications: Bachelor’s degree in mechanical engineering, physics, or similar engineering discipline 2+ years of process development experience in advanced CNC machining, specifically involving hard metals and complex toolpath geometries Hands-on experience (professional or academic) with CAM programming and operating CNC equipment Fundamental understanding of mechanical physics, including material properties and the mechanics of material removal Experience gathering and processing data sets from manufacturing equipment to drive process improvements Nice to Have: Master’s or PhD (strongly preferred) in mechanical engineering, physics, or similar engineering discipline Research experience in machining or similar manufacturing disciplines Experience with difficult-to-machine materials such as nickel-based superalloys (Inconel), titanium, or other difficult metals Familiarity with programming languages such as MATLAB, Python, or R for developing semi-mechanistic cutting models Experience with metrology systems (CMM, PC-DMIS) and designing automated inspection fixtures Passion for solving audacious problems Desire to build the future of autonomous manufacturing from the ground up Location: Based in Hawthorne, our vertically integrated facility brings technology development, RD, and production together under one roof. ... (truncated, view full listing at source)