R&D Laser Process Engineer

We are looking for a Laser Process Engineer to join our Rapid Prototype Development group within the Metals R&D team. Servicing a broad range of Gore Medical customer teams, you will help deliver high-precision metal implant and delivery system components using state-of-the-art laser cutting, heat treatment, electropolishing, and automated inspection systems. You will initially engage in hands-on laser process development - ability to run laser processes, cut parts and troubleshoot systems, while also developing and improving new and existing laser-based processes through hands-on experimentation, prototype development, optical system design, automation, and data-driven process optimization.

Long-term, you will be expected to engage in other aspects of process development for laser-cut metallic and non-metallic medical device components - from proof-of-concept prototypes to sustained manufacturing validation - planning, and coordinating engineering activities, capability studies, and root cause investigations in support of standard production and new product development.

This role will be located at our facility in Flagstaff, Arizona.

• Safely and efficiently operate state-of-the-art laser, heat treatment, and electropolishing processes.
• Develop novel laser applications (cutting, ablation, welding) and specify high-performance laser sources and optical delivery systems
• Design and execute complex Design of Experiments (DOE) to map the process window and optimize laser process parameters
• Generate custom laser processing toolpaths using CAD/CAM software and post processing scripts, including use of Aerotech CADFusion software.
• Design and fabricate custom fixtures to position complex prototype parts during laser processing and inspection, including the use of 3D printing technology
• Verify conformance to specifications and perform measurement system analysis (e.g., Gage R&R, bias, linearity) to ensure inspection reliability using appropriate inspection systems (e.g. Visicon, Nikon, Sensofar, tool scope, etc)
• Generate machine specifications, process documentation, experimental work plans, and manufacturing instructions. Deliver presentations on your work to peers and project customers.
• Perform all aspects of building medical device proof-of-concept prototypes, including material preparation, post processing steps (i.e. de-chipping, cleaning, packaging, etc.), and maintaining traceability.
• Perform routine calibration, daily system checks, and preventative maintenance on laser systems. Coordinate with equipment vendors for advanced maintenance needs.
• Maintain a clean and organized lab environment through active support of R&D Lab 6S principles. When needed, manage operations for the Rapid Prototype Development group, including scheduling of Metals R&D lab resources, tracking of appropriate metrics, and managing relationships with project team customers.

• Bachelor of Science in an applicable technical field (e.g. Mechanical Engineer, Physics, Material Science, Computer Science, etc.)
• A minimum of 3 years of industrial manufacturing or R&D process support experience
• A minimum of 2 years experience with Solid Works CAD modeling for rapid fixture development
• Proficiency using CAD/CAM software, such as Solid Works, AlphaCAM, Aerotech CADFusion, or similar
• Proficiency using statistical analysis software, such as JMP, Minitab, etc
• Proficiency writing and implementing reports within an industry with ISO certified quality system
• Demonstrated history of providing excellent customer service through strong verbal communication and emotional intelligence
• Strong time management and organizational skills
• Hands‑on mechanical aptitude with physical ability to: lift up to 25…