Manufacturing Engineer-Photonics

Job Title: Manufacturing Engineer

Location: Bedford, MA

Division: Photonics

Department: EM4

Position Description:

As the Manufacturing Engineer – Automation & Fiber Alignment, you will be responsible for developing, sustaining, and continuously improving the automated and semi‑automated manufacturing systems that enable production of our advanced laser products. This is a hands‑on role at the heart of production, driving yield, throughput, and process stability.

You will collaborate closely with Manufacturing, Process Engineering, Quality, and R&D to transition robust processes from development into volume manufacturing and support them throughout the product lifecycle. You will play a key role in scaling precision photonics assembly processes—particularly in fiber alignment and attach—and ensuring they remain reliable, controlled, and manufacturable at scale.

Duties and Responsibilities:

Automation Ownership

• Design, develop, and sustain automated and semi‑automated equipment for laser assembly, including motion systems, machine vision, metrology, dispense/weld tools, and UV/thermal cure platforms.
• Specify and integrate precision automation components such as stages, controllers (PLC/industrial PC), sensors, interlocks, and data‑acquisition systems.
• Create and maintain equipment requirements, acceptance criteria, and run‑at‑rate plans; lead factory acceptance and production release.
• Define preventive maintenance plans, calibration strategies, spares lists, and overall equipment lifecycle management.
• Drive equipment reliability improvements using uptime metrics, structured root‑cause analysis, and corrective actions.
• Perform CAD/mechanical design for fixtures, tooling, and assembly/test stations.

Fiber Alignment & Fiber Attach Process Engineering

• Own the full fiber alignment and attach process—from active alignment through attach (epoxy or laser weld), cure, and post‑cure verification.
• Develop and control process windows for critical parameters such as alignment algorithms, coupling optimization, welding conditions, adhesive selection, cure profiles, thermal management, and mechanical fixturing.
• Define and execute DOE‑based process characterization for coupling efficiency, back‑reflection, power stability, and long‑term reliability.
• Establish in‑line controls and acceptance tests, including insertion/return loss, power stability, pull/shear strength, and visual/AI‑based inspection.
• Write and maintain work instructions, process specs, travelers, and training documents to ensure consistent execution across operators and shifts.

Yield, Quality, and Scale

• Lead structured problem solving for yield loss and defects using 8D, DMAIC, fishbone, Pareto, and statistical methods.
• Implement SPC, control plans, MSA/Gage R&R, and traceability systems for critical‑to‑quality characteristics.
• Partner with Quality on nonconformance disposition, CAPAs, and audit readiness.
• Support NPI activities: process transfer from R&D, DFM/DFS feedback, pilot builds, and ramp into stable production.

Data Systems & Documentation

• Build data pipelines from equipment into MES/SPC systems; define dashboards, alarms, and drift‑detection criteria.
• Maintain complete technical documentation, including PFMEA, process flows, control plans, equipment manuals, and validation reports.
• Required Skills and Experience:
• Bachelor’s degree in Mechanical, Manufacturing, Electrical, Mechatronics, or related engineering field (MS/PhD a plus).
• 5+ years of manufacturing engineering experience in precision assembly; photonics/laser experience strongly preferred.
• Demonstrated experience developing or supporting automation equipment in a production environment.
• Proven ability to improve critical processes using DOE, SPC, and root‑cause methodologies.
• Comfortable in a hands‑on manufacturing environment, including troubleshooting, fixture tuning, and rapid iteration.
• Proficiency in SolidWorks. Required Skills and Experience
• Bachelor’s degree in Mechanical, Manufacturing, Electrical, Mechatronics, or related engineering field (MS/PhD a plus).
• 5+ years of manufacturing engineering experience in precision assembly; photonics/laser experience strongly preferred.
• Demonstrated experience developing or supporting automation equipment in a production environment.
• Proven ability to improve critical processes using DOE, SPC, and root‑cause methodologies.
• Comfortable in a hands‑on manufacturing environment, including troubleshooting, fixture tuning, and rapid iteration.
• Proficiency in SolidWorks. Preferred Qualifications
• Experience with active fiber alignment (power maximization, 5–6 DOF, machine‑vision‑assisted strategies).
• Familiarity with laser welding and adhesive/epoxy attach processes including UV/thermal cure and contamination control.
• Background in motion control: precision stages, encoders, PID tuning, error budgeting, vibration/thermal effects.
• Programming/scripting skills in Python, LabVIEW, C#/C++, or similar; PLC/HMI exposure a plus.
• Knowledge of optical metrology and inspection tools (power meters, photodiodes, interferometry, microscopes, vision systems).
• Experience with ESD, clean handling, and contamination control in photonics assembly.
• Familiarity with ISO 9001/AS9100 environments.