Senior Photonics Process Development Engineer Packaging and Tooling

Join our fast-paced and passionate team as a Senior Photonics Process Development Engineer focused on advanced packaging and tooling. As we scale, you will be instrumental in building our manufacturing foundation from the ground up. This is a dynamic, hands‑on role for a highly self‑directed engineer who thrives in an ambiguous, fast-moving environment.

You will play a critical role in establishing scalable photonic manufacturing processes that directly enable product performance, reliability, and cost targets. Your work will contribute to how our technology transitions from prototype to production.

You will collaborate closely with device, optical, electrical, mechanical, and manufacturing engineers to transform delicate photonic designs into robust, manufacturable, high-yield products.

• Determine core assembly and packaging processes that enable company growth
• Create manufacturing strategies that scale from R&D to production
• Improve yield, reliability, and cost through process innovation and optimization
• Build tooling, fixtures, and automation approaches that enable repeatability

• Vacuum reflow soldering (AuSn, SAC, Indium, and related materials)
• Wire bonding (Au and Al; ball and wedge)
• Die bonding (epoxy, eutectic, and solder attach)
• Optical assembly and active alignment (lenses, isolators, fiber arrays)
• Fiber splicing and precision fiber handling (including PM alignment)
• Hermetic sealing (laser welding, parallel seam sealing)
• Adhesives and material characterization
• Process metrology and inspection (shear/pull testing, vision systems, interferometry, hermeticity testing)
• Automation and semi‑automation development

• Participates in end‑to‑end development of photonic assembly processes from concept through production release
• Create and execute the process development roadmap aligned with product and manufacturing goals
• Design statistically rigorous experiments (DOE) to optimize process windows, robustness, and yield
• Determine process control limits, qualification criteria, and acceptance metrics
• Transition processes from R&D to pilot and full manufacturing scale
• Process transfer to production, including equipment qualification (IQ, OQ, PQ)
• Work on yield improvement initiatives and root‑cause investigations for failures and reliability issues
• Participate in establishing engineering standards, documentation, and best practices
• Create process flows, work instructions, travelers, and training materials
• Apply Design for Manufacturability (DFM) principles and perform tolerance analysis
• Analyze and improve process capability (Cp/Cpk)
• Support qualification, reliability testing, and failure analysis (including FMEA)
• Perform precision fixtures, tooling, and mechanisms to enable repeatable assembly and alignment
• Collaborate with mechanical engineers and equipment vendors to develop manufacturable solutions and automation
• Ensure adherence to cleanroom protocols and contamination control practices
• Perform other related duties as required.

• This position requires access to export‑controlled information. Employment is contingent upon the applicant being a U.S. person as defined by 8 U.S.C. § 1324b(a)(3).

• BS or MS in Optical Engineering, Electrical Engineering, Materials Science, Mechanical Engineering, Physics, or a related field.
• 5+ years of relevant experience in photonics or optoelectronic process development.
• 3+ years of experience using manufacturing process equipment such as die bonders, wire bonders, vacuum reflow systems, active alignment platforms, or laser welding systems

• Experience with laser diodes, PICs, modulators, detectors, or optical transceivers
• Familiarity with hermetic packaging (butterfly, TO, or micro‑optical packages)
• Experience with active alignment systems
• Reliability testing experience (thermal cycling, HTOL, damp heat)
• Knowledge of statistical process control (SPC) and manufacturing metrics
• Experience supporting low- to medium‑volume production environments
• Fixture and mechanism design experience in precision systems

• Comfortable operating in an evolving environment with changing priorities
• Motivated by building new capabilities…