The Person Behind the Process
There is a moment that happens in manufacturing when experience takes over.
The machine is running. The part is complex, maybe this is one step in a series. Everyone on the floor knows there is no shortcut.
That moment has been repeating itself for more than 45 years of Dan Costello’s life.
Today, after nearly a quarter of a century with KMM, he remains one of the people others turn to when the difficult jobs show up.
“I primarily program and operate Wire EDM machines and engineer new jobs,” Dan explains. “I also handle many of the more complicated jobs and perform machine repairs when necessary.”
That description sounds simple enough. But anyone who has spent time around manufacturing knows there is a difference between running a machine and understanding it.
Learning the Wire EDM Craft from the Beginning
Dan belongs to a generation of craftsmen who learned their trade by solving problems one at a time, long before software or AI could provide all the answers.
His journey began in 1979 through a Tool and Die apprenticeship. The Wire EDM technology he learned on would be considered primitive by today’s standards. Yet the fundamentals never changed. Learn the process. Understand the machine. Keep improving.
Those lessons are what guide him to make some of the most challenging and failure-intolerant components in MedTech, Space Exploration, and other critical industries.
The reason he’s stayed at KMM for so long has little to do with machines.
“KMM has treated me respectfully and always ensured I know I’m appreciated,” he says. “Eric [Wilhem, KMM’s President] inspires me to do my best work, challenging me with new projects while giving me his full support to succeed.”
That support matters because the work is always challenging.
Problem Solving Under Pressure
In extreme precision manufacturing, there are days when nothing seems to cooperate. Programs need adjustment. Parts don’t behave as expected. Problems appear where none existed before.
When asked what it takes to deliver high-quality work, Dan laughs a little at his own answer.
"While some might call it stubbornness, strong determination allows me to persevere when a job isn't going smoothly."
Call it determination. Call it persistence. Whatever name you choose, it has helped produce some remarkable accomplishments.
Three stand out in particular:
- Successfully working with incredibly fragile and difficult to manipulate .002” wire.
- Creating a program that uses variables and trigonometry to orient parts with exceptional precision.
- And developing an advanced robotic loading system that keeps two Wire EDM machines running around the clock.
Each achievement solved a different problem. Together, they reveal something larger. Dan has never been satisfied with simply getting the job done. He's always looked for a better way.
Building Trust Through Reliability
"When a project goes well, it gives me a sense of accomplishment," he says. "It makes me feel good that the company, and our customers, can rely on me."
Reliability is an underrated quality.It rarely gets headlines. It doesn't announce itself. Yet the best companies are built on people who consistently show up, solve problems, and help others succeed. Dan’s vision for the future of KMM reveals that same mindset.
"KMM has always been known for its high-end precision work,” Dan reflected. “I believe everyone here will help the company continue to grow as we take on more complex and challenging projects knowing we have top-notch personnel in every department, including Wire EDM."
That says a lot. After decades of solving challenges, Dan’s skills have evolved far beyond seeking personal validation for a job well done. He’s simply confident that when the difficult work arrives, the right people are already in place.
Beyond the Shop Floor
Many may believe that manufacturing is just grinding away at machines all day. Spend five minutes talking with Dan and that idea falls apart.
He's spent most of his life making music, picking up instruments, recording songs in a basement studio, and chasing ideas simply because they interested him. These days, you'll also find him on a golf course with his daughter Bethany or watching golf tournaments with his wife, Patty, on a quiet weekend afternoon.
Simply put, he’s the kind of person people want beside them at work.
When asked for his favorite quote, Dan points to a line from Led Zeppelin’s Stairway to Heaven:
“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.”
Maybe that’s why the song has endured for so many years. It reminds us that no matter where we start, we’re never locked into a single path.
The Secret Behind Long Careers
Dan’s path began with a primitive Wire EDM machine nearly five decades ago. It led to a career built on trust, craftsmanship, and relationships that lasted nearly 24 years.
Not everyone stays somewhere that long. People usually do when they enjoy the work, respect the people around them, and feel respected in return.
The next great manufacturing career doesn’t always begin with a perfect résumé. Sometimes it begins with curiosity, a willingness to learn, and a team that invests in your growth. If you’re ready to build something meaningful, explore our current career opportunities and see where your story could begin.
A Wire EDM Specialist programs and operates Wire Electrical Discharge Machining equipment to manufacture highly precise components with complex geometries and tight tolerances.
KMM serves industries including medical device manufacturing, aerospace, defense, space exploration, and other high-precision applications requiring exceptional accuracy.
Wire EDM removes material using controlled electrical discharges rather than cutting tools, making it ideal for intricate features, difficult materials, and extremely tight tolerances.
Technical knowledge, persistence, problem-solving ability, attention to detail, and a commitment to continuous improvement are critical for success in high-precision manufacturing environments.