Senior Process Engineer

Key Responsibilities

• Active Alignment Process Development

• Lead development of active alignment processes for optoelectronic, photonic, laser, sensor, fiber-coupled, and optical module assemblies.
• Translate customer requirements into practical process development plans, including alignment strategy, test feedback method, process sequence, inspection approach, and risk mitigation.
• Develop process parameters for optical coupling, alignment, fixation, adhesive dispense, cure, and post-process verification.
• Identify and control variables affecting optical performance, alignment stability, yield, and repeatability.
• Support feasibility builds, prototypes, process optimization, and low-volume contract manufacturing projects.

• Serve as the internal technical owner for their active alignment system and projects.
• Complete in-depth equipment training directly with the equipment manufacturer and convert that knowledge into usable internal practices.
• Develop, modify, and debug equipment routines, process sequences, and machine workflows.
• Learn and manage the equipment’s software environment, including any script-like or coding-style interface required to operate the system effectively.
• Establish internal best practices for equipment setup, calibration, maintenance coordination, program control, and process transfer.
• Troubleshoot equipment, software, motion, vision, dispense, and test feedback issues as they arise.

• Serve as the primary technical liaison for active alignment customer inquiries, development programs, and project execution.
• Support Sales and Program Management during technical discovery, feasibility review, quoting, and proposal development.
• Communicate clearly with customers regarding technical requirements, risks, process assumptions, development progress, and recommended paths forward.
• Help customers understand design-for-manufacturability considerations related to active alignment and optoelectronic assembly.
• Build customer confidence in Palomar’s new active alignment capability through professional, technically grounded communication.

• Create internal documentation for active alignment processes, machine operation, troubleshooting, calibration checks, and standard work.
• Develop process travelers, set up checklists, inspection criteria, and customer-specific work instructions.
• Capture lessons learned from development programs and convert them into reusable knowledge for future projects.
• Train other ASD engineers and technicians as the capability matures.
• Help establish active alignment as a scalable service offering within ASD.

• Work closely with Process Engineering, Engineering Operations, Program Management, Sales, Quality, and Operations.
• Collaborate with other ASD engineers on related packaging processes such as die attach, dispensing, curing, inspection, and optical/electrical testing.
• Coordinate with external equipment support when needed to resolve machine issues or expand equipment functionality.
• Support ASD’s broader growth strategy by helping convert a new equipment investment into a reliable, revenue-generating capability.

• Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Optical Engineering, Materials Science, Physics, or related technical field.
• 5+ years of relevant experience in process engineering, photonics assembly, optoelectronics packaging, precision alignment, or related manufacturing/process development environments.
• Hands-on experience with active alignment, optical alignment, fiber coupling, laser alignment, photonic device packaging, or similar precision optoelectronic assembly processes.
• Familiarity with optoelectronic devices and assemblies such as laser diodes, photodiodes, optical transceivers, photonic integrated circuits, fiber-coupled packages, cameras, sensors, or LiDAR modules.
• Experience working with optical or electrical feedback during alignment or assembly.
• Strong troubleshooting ability across equipment, process, material, software, and measurement variables.
• Demonstrated ability to…