Employee Spotlight: Wire EDM Specialist & Engineer Dan Costello

Wire EDM Dan Costello Employee Spotlight

The dedication of our team makes KMM’s remarkable achievements possible. Through our Employee Spotlight series, we shine a light on the individuals who work tirelessly behind the scenes, significantly contributing to our success and the manufacturing industry overall. Today, we are featuring Dan Costello, who joined KMM in October 2002. With over 22 years of experience here, Dan is a skilled wire EDM specialist and engineer.

Q: Describe your role at KMM. 

DC: I primarily program and operate Wire EDM machines and engineer new jobs, including the processes required to make the part and any fixturing that might be needed. I also handle many of the more complicated jobs and perform machine repairs when necessary.

Q: What has motivated you to stay at KMM for over two decades? 

DC: KMM has treated me respectfully and always ensured I know I’m appreciated. Eric [Wilhelm], KMM’s president, inspires me to do my best work, challenging me with new projects while giving me his full support to succeed.

Q: What does it take to deliver high-quality work in your role?

DC: While some might call it stubbornness, strong determination allows me to persevere when a job isn’t going smoothly.

Q: Which career accomplishments are you most proud of?

DC: Three accomplishments stand out:

  1. Successfully working with .002” diameter wire, which is incredibly difficult and fragile.
  2. Creating a program that orients parts using variables and trigonometry to make each part exactly right.
  3. Developing an elaborate robotic part loader program to keep two machines running around the clock.                  

Q: What is your vision for the future at KMM? 

DC: KMM has always been known for its high-end precision work. I believe everyone here, including me, will continue to help the company grow as we take on more complex and challenging projects.

Q: What effect do you want to have on KMM with work?

DC: I want the company to continue pursuing difficult projects, knowing they have top-notch personnel in every department, including wire EDM.

Q: What is the most rewarding part of your job?

DC: When a project goes well, it gives me a sense of accomplishment and makes me feel good that the company can rely on me.

Q: Where did you receive your education?

DC: I served a Tool and Die Apprenticeship starting in 1979, which included learning Wire EDM on a very primitive machine. I’ve been doing this for 45 years, with the last 22 at KMM. I also briefly attended Temple University, studying Mechanical Engineering.

Q: What are your hobbies or personal interests?

DC: I’ve been a musician for most of my life, playing many different instruments, though none very well. I have a studio in the basement where I make recordings for myself when I get the time. I also enjoy occasional rounds of golf with my daughter Bethany, and most weekends, I find time to watch golf on TV with my wife, Patty.

Q: What is your favorite quote?

DC: “Yes, there are two paths you can go by, but in the long run, there’s still time to change the road you’re on.”   – “Stairway to Heaven” by Led Zepplin

We want to thank Dan for sharing his story and insights, and for his gracious and lengthy service at KMM. His expertise and dedication exemplify our fundamental values, and we look forward to continuing to achieve excellence together.