Fiber Optics Manufacturing Engineer

Commonwealth Fusion Systems•Somerville, MA

1d•Hybrid

About The Position

Commonwealth Fusion Systems (CFS) is seeking a Fiber Optics Manufacturing Engineer to join their mission of delivering fusion energy. This role is critical in developing, scaling, and improving manufacturing processes for fiber optic cables and assemblies. The engineer will collaborate with various cross-functional teams, including Fiber Optic Specialists, design engineering, quality, test, and supply chain, to transition products from development to reliable production. The position requires a blend of manufacturing engineering fundamentals and an understanding of fiber optic processes and product requirements, aiming to translate hands-on expertise into robust manufacturing systems, tooling, documentation, and controls for high-quality, high-yield production. This role involves work at both the Devens, MA and Somerville, MA locations.

Requirements

Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Optical Engineering, or equivalent work experience.
5+ years of manufacturing engineering experience, including experience developing or improving fiber optic, optical, cable assembly, precision assembly, or other technically sensitive manufacturing processes.
Experience working directly with fiber optic manufacturing, cable assembly, optical fiber handling, splicing, testing, or related precision processes.
Strong understanding of manufacturing process development, process control, troubleshooting, and continuous improvement.
Experience with Lean Manufacturing, Six Sigma, RCCA, DOE, SPC, process capability, or other structured problem-solving methodologies.
Strong analytical and problem-solving skills, with the ability to use manufacturing and test data to identify root causes and drive process improvements.
Excellent communication and interpersonal skills, with the ability to work effectively with engineers, Fiber Optic Specialists, technicians, quality, test, and other cross-functional teams.
Ability to work effectively in a fast-paced, dynamic environment and manage multiple priorities.
Strong attention to detail and commitment to safety, quality, and execution.
Ability to lift up to 50 lbs occasionally.
Perform activities such as typing, standing, stooping, and sitting, for extended periods of time.
Dedication to safety to mitigate hazards that may include heat, cold, noise, fumes, strong magnets, lead, high voltage, and cryogenics.
Willingness to occasionally travel or work required nights/weekends/on-call.

Nice To Haves

Experience with fiber optic cable manufacturing, fiber routing, splicing, termination, wrapping, jacketing, or optical assemblies.
Experience with optical performance measurements such as attenuation, insertion loss, continuity, spectral analysis, or related fiber optic test methods.
Familiarity with OTDR, OSA, OBR, optical power meters, or other fiber optic test equipment.
Experience working with coated, polyimide, or other specialty fibers.
Experience with fiber proof testing or other mechanical qualification methods.
Experience developing processes for products with tight mechanical, geometric, or optical requirements.
Experience designing or procuring manufacturing equipment, tooling, fixtures, and process controls.
Experience with CAD software and the ability to read and understand technical drawings, including GD&T and tolerance stack-ups.
Proficiency in work instruction writing, process mapping, time studies, capacity modeling, and manufacturing data analysis.
Experience developing equipment specifications and maintenance plans.
High self-motivation and drive to execute quickly with excellent troubleshooting and problem-solving skills.

Responsibilities

Partner with Fiber Optic Specialists and production teams to develop, standardize, and continuously improve fiber optic manufacturing processes.
Transition fiber optic products and processes from R&D and prototype builds into repeatable, scalable production.
Develop, implement, and qualify manufacturing processes for fiber optic cables and assemblies, balancing quality, optical performance, throughput, cost, and production rate.
Develop and optimize processes for fiber handling, routing, splicing, wrapping, jacketing, bonding, termination, and cable assembly.
Develop manufacturing processes and controls that prevent fiber damage, including excessive bending, pinching, tension, handling, routing, and other sources of optical or mechanical degradation.
Develop and optimize tooling, fixtures, equipment, and workstations to enable repeatable fiber optic manufacturing while protecting sensitive fiber and cable components.
Partner with Design Engineering to apply Design for Manufacturing (DFM) and Design for Assembly (DFA) principles and ensure product designs are manufacturable at production scale.
Establish manufacturing process parameters, acceptance criteria, inspection methods, and process controls for critical fiber optic processes.
Create and maintain manufacturing documentation, including work instructions, process flow diagrams, pFMEAs, standard operating procedures (SOPs), and process control plans.
Partner with Quality and Test Engineering to develop effective inspection and test methods for critical fiber optic requirements.
Use manufacturing and optical performance data to identify sources of variation, establish process capability, and improve first-pass yield, scrap, rework, cycle time, and throughput.
Troubleshoot manufacturing and quality issues using structured root-cause analysis, experiments, data analysis, and hands-on investigation.
Lead continuous improvement and RCCA projects that improve manufacturing yield, reduce fiber damage and scrap, and increase process robustness.
Provide hands-on technical support and training to Fiber Optic Specialists and production personnel on processes, tooling, equipment, work instructions, and best practices.
Support manufacturing capacity planning, equipment requirements, production readiness, and process scaling.
Ensure manufacturing processes meet applicable safety, quality, and production requirements.