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Key Responsibilities and Required Skills for Heat Cutter

💰 $ - $

ManufacturingProductionCNCFabricationQuality Control

🎯 Role Definition

The Heat Cutter (also known as Thermal Cutting Operator or Hot Wire/Hot Knife Operator) is responsible for precision cutting of foam, fabric, composites, plastics and other materials using heat-based cutting equipment — including manual hot knives, hot-wire tables, and CNC thermal cutting systems. The role emphasizes accurate setup, machine programming or pattern nesting, temperature and feed-rate control, safety and preventive maintenance, quality inspection, and continuous improvement to meet production schedules, tolerance specifications, and quality standards such as ISO/TS or customer requirements.

This position requires strong mechanical aptitude, experience with CNC or semi-automated thermal cutting systems, the ability to read technical drawings and cutting patterns, and a commitment to workplace safety and defect-free output.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Production Operator / General Manufacturing Associate
  • CNC Machine Operator or Woodworking/Metalworking Machine Operator
  • Sewing, Upholstery or Foam Fabrication Technician

Advancement To:

  • Senior Heat Cutter / Lead Cutting Operator
  • CNC Programmer / Nesting Specialist
  • Production Supervisor or Manufacturing Team Lead
  • Manufacturing Process Engineer (foam/composite/fabric processes)

Lateral Moves:

  • Quality Inspector / SPC Technician
  • Maintenance Technician / Industrial Mechanic
  • Material Prep / Pattern Maker

Core Responsibilities

Primary Functions

  • Set up and calibrate hot-wire tables, hot-knife stations, CNC thermal cutting machines, and associated fixtures according to job tickets, technical drawings and material specifications to ensure accurate cuts and efficient production throughput.
  • Interpret blueprints, CAD patterns, cutting nests, and work orders to program or manually set cutting paths, sequence operations, cut order and orientation to minimize material waste and meet dimensional tolerances.
  • Program CNC thermal cutting equipment or import nesting files (DXF/CSV) into the machine control, verify G-code or toolpaths, run simulation checks, and make on-machine adjustments to cutting speed and temperature for optimal results.
  • Monitor temperature, power, feed rate, blade/wire tension and machine speed throughout the cutting cycle and make timely corrections to maintain dimensional accuracy and prevent burning, fraying or material deformation.
  • Select and maintain appropriate cutting elements (wires, blades, tips, cartridges) and consumables, including documenting use and reordering consumables to prevent production delays.
  • Perform first-article inspections and in-process dimensional checks using calipers, micrometers, templates and gauges; record results and immediately correct any process deviations to prevent scrap.
  • Execute quality control measures and follow customer-specific inspection criteria and standards (e.g., ISO 9001, AS9100) to ensure parts meet visual, dimensional and functional requirements.
  • Troubleshoot electrical, mechanical and thermal issues on hot-cutting equipment; isolate causes (temperature control, drive system, wiring, software) and perform basic repairs or coordinate with maintenance to minimize downtime.
  • Maintain accurate production logs, cutting parameters, scrap reports and material yield statistics to support process improvement and cost-control initiatives.
  • Load and secure raw materials and blanks safely, verify material type and lot numbers, and ensure proper orientation and nesting to optimize yield and avoid defects.
  • Collaborate with engineering and CAD/Nesting teams to refine cutting patterns, reduce material usage, and improve cycle times through continuous improvement and design-for-manufacturability practices.
  • Adhere to and promote all safety, PPE and lockout/tagout procedures while operating hot cutters and related equipment to prevent burns, inhalation hazards and mechanical injury.
  • Conduct routine preventive maintenance inspections including cleaning burners/heaters, replacing belts/filters, and lubricating moving components; document maintenance actions and escalate complex repairs.
  • Train new and cross-functional operators on heat cutting processes, machine safety, quality expectations and best practices to ensure consistent output across shifts.
  • Manage production priorities, coordinate with scheduling and material planning teams, and adjust workflows to meet changing daily priorities or rush orders.
  • Participate in root cause analysis for rejects and returns, implement corrective actions (process adjustments, operator training, tooling changes) and monitor effectiveness over time.
  • Maintain housekeeping standards around cutting stations, including proper disposal of scrap, minimization of combustible dust accumulation and control of fumes using extraction systems.
  • Optimize cut order and nesting strategies to reduce cycle time and raw material consumption while maintaining required part orientation and grain considerations for fabric or composite materials.
  • Ensure traceability by labeling batches and finished parts with job numbers, lot codes and inspection stamps according to company and customer requirements.
  • Assist in material selection and advise production and procurement teams on suitable temperature settings, consumables and fixture designs for new products or prototype runs.
  • Support continuous improvement initiatives such as 5S, Kaizen events and process documentation updates to enhance throughput, safety and quality of the heat cutting operation.
  • Provide end-of-shift handover notes, highlight open issues, and communicate upcoming tooling or maintenance needs to the incoming shift to ensure production continuity.

Secondary Functions

  • Help evaluate capital equipment performance and provide operator feedback during purchase and qualification of new heat cutting systems and extraction/filtration equipment.
  • Support inventory control by conducting cycle counts of blades, wires and spare parts, and recommending minimum stock levels to prevent production interruptions.
  • Participate in cross-functional meetings with engineering, quality, and production planning to refine lead times and validate capacity for new product introductions.
  • Complete basic administrative tasks such as scanning paperwork, updating job statuses in ERP/MRP systems, and logging machine runtime and downtime events.
  • Assist maintenance technicians with diagnostics during complex repairs and provide operator-level observations to speed fault resolution.
  • Contribute to safety committees and environmental compliance efforts by reporting potential hazards, improving ventilation or fume capture and ensuring proper waste disposal of contaminated materials.

Required Skills & Competencies

Hard Skills (Technical)

  • Proficient operation of hot-wire cutting tables, hot-knife stations and CNC thermal cutting systems (manual and automated).
  • CNC programming basics and ability to import and edit nest files (DXF, CSV) and work with machine controllers; familiarity with common controllers and G-code troubleshooting.
  • Experience with pattern nesting software (NestFab, SigmaNEST, Optitex, or equivalent) and CAD drawing review for nesting optimization.
  • Strong ability to read and interpret technical drawings, blueprints, DXF files, BOMs and cutting patterns with dimensional tolerance awareness.
  • Hands-on experience setting temperature, feed rate, tension and speed for different materials (polyurethane foam, polyester batting, composite core, thermoplastics, fabric).
  • Competence in first-article inspection and use of measurement tools: calipers, micrometers, thickness gauges, templates and optical comparators.
  • Preventive maintenance and basic mechanical/electrical troubleshooting skills for heaters, motors, drive belts and wiring.
  • Knowledge of material handling practices, proper storage for combustible/flammable materials and use of hoisting or forklift equipment (if applicable).
  • Familiarity with quality systems and documentation practices (e.g., ISO 9001, SPC charts, NCR handling, corrective action tracking).
  • Experience with shop floor data entry into ERP/MRP systems and ability to maintain accurate production logs and traceability records.
  • Ability to set up and maintain appropriate PPE and fume extraction/filtration systems to comply with OSHA and local environmental regulations.
  • Experience implementing and participating in Lean manufacturing practices such as 5S, Kaizen and waste reduction related to cutting operations.

Soft Skills

  • Strong attention to detail with a commitment to producing defect-free parts and maintaining tight tolerances.
  • Good mechanical aptitude and problem-solving skills with a practical “hands-on” approach to machine diagnostics.
  • Clear verbal and written communication skills for documenting issues, training peers and participating in cross-functional meetings.
  • Time management and ability to prioritize tasks in fast-paced production environments with changing daily schedules.
  • Team player mindset and willingness to support other production areas during high-demand periods and continuous improvement initiatives.
  • Adaptability and openness to feedback when implementing new processes or equipment upgrades.
  • Customer-focused mentality with a proactive approach to meeting delivery dates and quality expectations.

Education & Experience

Educational Background

Minimum Education:

  • High school diploma or GED required.

Preferred Education:

  • Technical certificate, vocational training or associate degree in Manufacturing Technology, Industrial Maintenance, CNC Technology or a related field.

Relevant Fields of Study:

  • Manufacturing Technology
  • Mechanical or Industrial Maintenance
  • CNC Machining / Programming
  • Composite Fabrication or Textile Technology

Experience Requirements

Typical Experience Range:

  • 1–5 years of hands-on experience in thermal cutting, foam/fabric cutting, CNC cutting or related manufacturing operations.

Preferred:

  • 3+ years of experience operating CNC thermal cutting equipment, hot wire/hot knife systems or experience in a production environment cutting foam, composites or technical textiles.
  • Experience with nesting software, G-code basics, and familiarity with quality systems (ISO/SPC) and safety standards (OSHA).
  • Prior exposure to lean manufacturing, preventive maintenance and cross-training on related equipment is strongly preferred.
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