Manufacturing Engineer - Photonics

As the Manufacturing Engineer – Automation & Fiber Alignment, you will be responsible for developing, sustaining, and continuously improving the automated and semi-automated manufacturing systems that enable production of our advanced laser products. This is a hands-on role at the heart of production, driving yield, throughput, and process stability. You will collaborate closely with Manufacturing, Process Engineering, Quality, and R&D to transition robust processes from development into volume manufacturing and support them throughout the product lifecycle. You will play a key role in scaling precision photonics assembly processes—particularly in fiber alignment and attach—and ensuring they remain reliable, controlled, and manufacturable at scale.

Responsibilities

Design, develop, and sustain automated and semi-automated equipment for laser assembly, including motion systems, machine vision, metrology, dispense/weld tools, and UV/thermal cure platforms; Specify and integrate precision automation components such as stages, controllers (PLC/industrial PC), sensors, interlocks, and data-acquisition systems; Create and maintain equipment requirements, acceptance criteria, and run-at-rate plans; lead factory acceptance and production release; Define preventive maintenance plans, calibration strategies, spares lists, and overall equipment lifecycle management; Drive equipment reliability improvements using uptime metrics, structured root-cause analysis, and corrective actions; Perform CAD/mechanical design for fixtures, tooling, and assembly/test stations; Own the full fiber alignment and attach process—from active alignment through attach (epoxy or laser weld), cure, and post-cure verification; Develop and control process windows for critical parameters such as alignment algorithms, coupling optimization, welding conditions, adhesive selection, cure profiles, thermal management, and mechanical fixturing; Define and execute DOE-based process characterization for coupling efficiency, back-reflection, power stability, and long-term reliability; Establish in-line controls and acceptance tests, including insertion/return loss, power stability, pull/shear strength, and visual/AI-based inspection; Write and maintain work instructions, process specs, travelers, and training documents to ensure consistent execution across operators and shifts; Lead structured problem solving for yield loss and defects using 8D, DMAIC, fishbone, Pareto, and statistical methods; Implement SPC, control plans, MSA/Gage R&R, and traceability systems for critical-to-quality characteristics; Partner with Quality on nonconformance disposition, CAPAs, and audit readiness; Support NPI activities: process transfer from R&D, DFM/DFS feedback, pilot builds, and ramp into stable production; Build data pipelines from equipment into MES/SPC systems; define dashboards, alarms, and drift-detection criteria; Maintain complete technical documentation, including PFMEA, process flows, control plans, equipment manuals, and validation reports

Requirements

Bachelor’s degree in Mechanical, Manufacturing, Electrical, Mechatronics, or related engineering field (MS/PhD a plus); 5+ years of manufacturing engineering experience in precision assembly; photonics/laser experience strongly preferred; Demonstrated experience developing or supporting automation equipment in a production environment; Proven ability to improve critical processes using DOE, SPC, and root-cause methodologies; Comfortable in a hands-on manufacturing environment, including troubleshooting, fixture tuning, and rapid iteration; Proficiency in SolidWorks

Nice to have

Experience with active fiber alignment (power maximization, 5–6 DOF, machine-vision-assisted strategies); Familiarity with laser welding and adhesive/epoxy attach processes including UV/thermal cure and contamination control; Background in motion control: precision stages, encoders, PID tuning, error budgeting, vibration/thermal effects; Programming/scripting skills in Python, LabVIEW, C#/C++, or similar; PLC/HMI exposure a plus; Knowledge of optical metrology and inspection tools (power meters, photodiodes, interferometry, microscopes, vision systems); Experience with ESD, clean handling, and contamination control in photonics assembly; Familiarity with ISO 9001/AS9100 environments