Manufacturing Engineer

Location: Middlefield

Are you ready to collaborate with leading experts in optical engineering and contribute to the next level of precision and innovation?

At Zygo, your skills and insights will be integral to our core values of curiosity, collaboration, and persistence. For over 50 years, Zygo Corporation in Middlefield, CT, has been a global leader in advanced optical metrology systems, ultra-precise optical components, and complex electro-optical systems. Join our team, where your expertise will drive innovative solutions, address complex technical challenges, and uphold the highest standards of precision and safety.

We are seeking a Manufacturing Engineer at our Middlefield, CT facility.

As a Manufacturing Engineer you will support the production of mechanical and opto‑mechanical products through process development, tooling design, documentation, and hands-on production support. This role is responsible for documenting assembly and test processes, designing mechanical fixtures and tooling, supporting new product introduction (NPI), and resolving production issues to ensure high-quality, repeatable manufacturing processes.

Key Responsibilities:

* Develop, document, and maintain detailed assembly and test work instructions, SOPs, visual aids, and bill of process (BOPs).

* Document optical and opto‑mechanical assembly methods, alignment procedures, and inspection criteria.

* Ensure manufacturing documentation supports repeatability, quality, safety, and training needs.

* Update documentation based on engineering changes, process improvements, and lessons learned.

* Design mechanical tooling, fixtures, gauges, and assembly aids to support mechanical and optical assembly processes.

* Develop tooling solutions to support optical alignment, handling, and precision fixturing.

* Coordinate fabrication and qualification of tooling with machine shops and external vendors.

* Validate tooling and fixtures through pilot builds and production trials.

* Support NPI projects from early development through production ramp-up.

* Collaborate with Design Engineering to ensure designs are manufacturable, testable, and scalable.

* Support DFM/DFA efforts for mechanical and optical assemblies.

* Participate in manufacturing readiness reviews (MRR), process flow development, and line set up for new products.

* Support process risk analysis activities (e.g., PFMEA) and production validation builds.

* Provide hands-on production floor support to troubleshoot assembly, test, and yield issues.

* Investigate and resolve process deviations, nonconformances, and product performance issues using structured problem-solving techniques such as 8D and RCCA.

* Support engineering change implementation and ensure minimal disruption to production.

* Train manufacturing and test personnel on new processes, tools, and equipment.

* Drive process improvements focused on quality, efficiency, ergonomics, and cost reduction.

* Support Lean manufacturing initiatives such as standard work, 5S, and Kaizen activities.

* Work closely with Quality Engineering on corrective and preventive actions.

* Interface with supply chain, engineering, and operations teams to resolve cross-functional issues.

Key Requirements:

* Bachelor's degree in Mechanical, Optical Engineering or related field.

* 3-5+ years of experience working with precision assemblies, optical components, and alignment-sensitive systems in a fast-paced manufacturing environment with direct shop-floor presence and involvement.

* Prior experience in regulated or high-reliability manufacturing environment is a plus.

* Detail-oriented mindset with strong technical documentation skills to support documenting assembly and test processes.

* Direct experience working on mechanical and optical assemblies.

* Experience with mechanical tooling and fixture design using Solid Works.

* Familiarity with optical components, alignment methods, or precision assemblies.

* Flexible and able to pivot with changing priorities; ability to manage multiple priorities and projects.

* Communicating and influencing skills that foster collaborative problem-solving across functions and levels, particularly between engineering design and manufacturing…