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.

Impact:

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

Key Technical Areas:

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

Responsibilities:

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.