lumilens - Active Alignment & NPI Process Development Engineer
Requirements
• Bachelor’s degree or higher in Engineering, Physics, Optics, Photonics, Mechanical Engineering, Electrical Engineering, or a related discipline. • Minimum 5 years of relevant experience with optical active alignment for transceivers or related photonic devices or related NPI/process development environment. • Hands-on experience developing and optimizing optical active alignment processes for transceivers or other photonic devices. • Familiarity with optical components and assemblies such as FAU, lenses, isolators, PICs, PD, laser, etc. • Experience with active alignment equipment development, setup, buyoff, qualification, and production deployment. • Strong understanding of motion stages, controllers, optical power meters, laser sources, cameras, sensors, and precision mechanical systems. • Experience developing or optimizing alignment algorithms and automated alignment sequences. • Knowledge of epoxy dispensing, adhesive bonding, UV curing, thermal curing, and associated material/process characteristics. • Experience with equipment control, automation, and process parameter optimization. • Experience in fixture and tooling development for precision optical assembly. • Demonstrated experience in NPI process development, process characterization, qualification, manufacturing transfer, and production ramp. • Experience with DOE, statistical process control, process capability analysis, Cp/Cpk, GR&R, and yield analysis. • Familiarity with PFMEA, Control Plans, SOPs, work instructions, process specifications, and manufacturing qualification documentation. • Ability to analyze complex process interactions across equipment, material, product design, tooling, and manufacturing conditions. • Strong troubleshooting, analytical, and structured problem-solving skills. • Ability to work effectively across R&D, manufacturing, equipment suppliers, quality teams, and contract manufacturers.
Responsibilities
• Lead manufacturing process development for new photonic products from prototype and engineering builds through NPI qualification and volume production. • Develop and optimize optical assembly processes including active alignment, passive alignment, epoxy dispensing, curing, optical coupling, and related assembly processes. • Define critical process parameters, critical-to-quality characteristics, process windows, acceptance criteria, and manufacturing specifications. • Plan and execute DOE, process characterization, tolerance studies, and process optimization activities to establish robust manufacturing processes. • Evaluate process capability and manufacturing performance using yield, Cp/Cpk, GR&R, and other statistical methods. • Support prototype, EVT/DVT/PVT, pilot, qualification, and production ramp builds. • Perform root-cause analysis on NPI build failures, yield excursions, and process-related defects and implement corrective actions. • Drive manufacturing yield improvement, cycle-time reduction, process simplification, and cost reduction during NPI and production ramp. • Develop and maintain process documentation including process specifications, work instructions, SOPs, PFMEA, Control Plans, qualification reports, and manufacturing readiness documentation. • Support DFM/DFA reviews and provide process-related feedback to product and mechanical design teams. • Lead manufacturing process transfer from R&D or development sites to internal factories, suppliers, or contract manufacturers. • Establish process controls and monitoring methodology to ensure stable manufacturing performance after production release.
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