CNC Programmer & Pattern Maker

SUMMARY
The CNC Programmer / Pattern Maker is the key technical resource responsible for leading KFI's
in-house pattern-making operation at the Portage facility. This person owns the entire pattern build
process from start to finish, including schedule management, CAM programming, CNC machining,
3D printed pattern trimming, finishing, and inspection. The role carries full accountability for pattern
completion dates and is expected to proactively communicate schedule status to Engineering and
Operations stakeholders.

ESSENTIAL DUTIES AND RESPONSIBILITIES include, but are not limited to, the following:

Wood & Ren Board Fabrication: Build, construct, and CNC machine master patterns, plugs, and molds from scratch using hardwood, plywood, Ren Shape/polyurethane tooling boards, and epoxy.
CNC Machining of 3D Printed Tools: Set up and operate 3-axis and 5-axis CNC routers and mills to precisely machine, trim, and finish 3D-printed polymer patterns into production-ready thermoforming plugs.
Aluminum Mold Maintenance & Modification: Modify, repair, and rework existing cast aluminum molds when engineering changes or production wear require updates; perform precise drilling, milling, and manual bench work on aluminum tooling.
Post-Processing & Surface Finishing: Sand, fill, polish, and apply heat-resistant coatings to machined 3D prints, wood, Ren board, and aluminum surfaces to achieve optimal, defect-free finishes.
Apply Draft & Venting: Inspect all tooling to guarantee proper draft angles for clean part release, and drill or clear precise vacuum vent holes to optimize production airflow.
CNC Programming & G-Code: Load, test, and optimize CNC programs; perform basic G-code edits at the controller to accommodate variations in wood, printed polymers, and cast aluminum.
Inspect & Verify: Use calipers, micrometers, and depth gauges to inspect finished tools, ensuring they maintain tight engineering tolerances (± 0.005").
Engineering Collaboration: Partner with the on-site design engineering team to provide feedback on 3D print machining allowances, material stock, and aluminum mold design updates.
Perform all duties in compliance with regulatory requirements as well as company policies and procedures

SUPERVISORY RESPONSIBILITIES None

QUALIFICATION REQUIREMENTS
To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

EDUCATION and/or EXPERIENCE

High school diploma/GED required; CNC machining certification, tool & die certification, or trade apprenticeship preferred.
3+ years of experience in CNC machining, pattern making, mold making, or precision tool/die fabrication.
Proven experience machining and working with a wide range of materials, including wood, Ren shape/tooling board, plastics (ABS), and metals (cast aluminum).
Proven track record setting up and running CNC mills or large-format routers. Strong traditional model shop bench-work skills are essential.
Strong ability to read 3D engineering files, blueprints, and geometric dimensioning and tolerancing (GD&T).

LANGUAGE SKILLS
Fluency in English is required. The ability to read, analyze, and interpret documents and the ability to effectively present information to all levels of employees including top management in a variety of settings is required.

REASONING ABILITY
Ability to define problems, collect data, establish facts, and draw valid conclusions. Ability to interpret an extensive variety of technical instructions in mathematical or diagram form and deal with several abstract and concrete variables.

PHYSICAL DEMANDS
The physical demands described in this section are representative of those that must be met by an employee to successfully perform the essential functions of this job. While performing the duties of this job, the employee is regularly required to stand, talk, walk, hear, reach with hands and arms, stoop and bend. The employee must seldom lift and/or move more than 25 pounds. Specific vision abilities required by this job include close vision, depth perception, color vision, and the ability to adjust focus. This position requires work around machinery, aluminum/wood chips, shop dust, and finishing resins.

WORK ENVIRONMENT
The work environment characteristics described in this section are representative of those an employee encounters while performing the essential functions of this job.

The production area temperatures can fluctuate significantly based on the time of year. The noise levels can be moderate to high. The use of hearing protection and safety eyewear is required while on production floor. The use of additional specific safety equipment may be required. The noise level in the office is usually quiet. The noise level in production is usually moderate.

WORK AVAILABLITY AND TRAVEL
Must have the ability to work all shift schedules, periodic overtime and be available for periodic weekend work. Travel requirements: <10%