Sr. Applications Engineer

EXALTA Group is looking for an experienced Sr. Applications Engineer to support sustaining and new product integration on milling platforms in our manufacturing plant making life-saving medical components that are used by surgeons in operating rooms across the world. 

Located on the shores of Lake Superior, our facility in Marquette, MI offers the rare combination of cutting-edge manufacturing and technology and unmatched outdoor lifestyle—from hiking and mountain biking to skiing, fishing, and exploring the beautiful Upper Peninsula.

Why Join EXALTA?

✔ Meaningful work – Manufacture precision components used in life-changing medical devices
✔ Career growth – Training, mentorship, and advancement opportunities. We want employees who will grow as we go. 
✔ Modern manufacturing environment – High-precision machining, automation, and advanced processes
✔ Team culture – Supportive environment focused on safety, quality, and continuous improvement

✔ Benefits – Robust benefits package, offering multiple medical plans, dental, visions, company paid disability and life insurance plans, 12 holidays per year, generous PTO accrual, 401k program with 6% employer match, and more! 

Location: Onsite in Marquette, MI

POSITION SUMMARY

The Sr. Applications Engineer serves as a technical expert in CNC programming and machining strategy for complex medical device components on Milling platforms. This role leads advanced programming initiatives, supports new product development, drives process optimization, and mentors programming and machining personnel. The Sr. Applications Engineer plays a key role in improving process capability, reducing cycle times, and ensuring scalable, validated manufacturing solutions.

ESSENTIAL RESPONSIBILITIES

• Lead development and optimization of complex CNC programs, including multi-axis and high-precision components
• Establish machining strategies for new product introductions and provide DFM feedback to Engineering
• Lead fixture and tooling design for complex geometries and tight-tolerance components
• Drive process validation activities including capability studies and statistical analysis
• Troubleshoot advanced machining challenges and lead root cause investigations
• Standardize programming methodologies and best practices across Milling and/or Swiss Turn platforms
• Mentor CNC Programmers, Set-Up Technicians, and CNC Machine Operators
• Evaluate and recommend new machining technologies, tooling, and automation solutions
• Support capital equipment justification, selection, and implementation
• Lead continuous improvement projects focused on cost reduction, scrap reduction, and cycle time optimization
• Develop accurate machining cost models and runtime estimates
• Ensure compliance with medical device quality systems and documentation standards
• Support audit readiness and regulatory compliance efforts

This is not an exhaustive list of duties and responsibilities.

EDUCATION & EXPERIENCE

• Associate’s or Bachelor’s degree in Engineering, Manufacturing, or related technical field or equivalent years of experience, required
• 8–12+ years of CNC machining experience in a production environment
• Advanced proficiency programming Milling equipment (experience with Swiss Turn platforms is a plus)
• Extensive experience in medical device manufacturing strongly preferred
• Experience with multi-axis machining and complex tight-tolerance components required

KNOWLEDGE, SKILLS & ABILITIES

Technical Competencies

• Advanced proficiency in CAM software and multi-axis CNC programming
• Expert-level GD&T interpretation and tolerance stack understanding
• Strong statistical analysis and process capability expertise
• Experience with process validation (IQ/OQ/PQ) in regulated environments
• Demonstrated ability to improve cycle times and reduce variation
• Experience implementing automation, tool monitoring, and adaptive control systems
• Strong understanding of cost modeling and machining economics

Leadership & Behavioral Competencies

• Recognized technical leader and subject matter expert
• Strong mentoring and coaching capability
• Excellent cross-functional communication and influence skills
• Strategic thinker with strong problem-solving ability
• High level of accountability and ownership
• Strong safety and quality mindset