Lead Sr. Optical Mfg. Engineer

AeroVironment•Albuquerque, NM

1d•Onsite

About The Position

The Manufacturing Engineering Team within our Space Technologies area is responsible for developing and scaling assembly, integration, and test operations for next-generation space systems, including optical payloads, laser communication terminals, and space-qualified hardware for satellite and orbital applications. As a critical member of this team, the Lead Optical Manufacturing Engineer will serve as the technical leader translating optical system designs (e.g., for laser comms, imaging, or stabilization payloads) from development into a sustainable, high-yield production environment. You will collaborate closely with design engineers, test engineers, systems engineers, and cross-functional teams to establish optical manufacturing processes and work instructions—from component assembly through final integration and qualification for space environments. This role is ideal for hands-on engineers who thrive on building and testing complex, high-precision optical products in cleanroom settings and take a methodical, innovative approach to pioneering and scaling production for defense and space missions. This is a full-time, in-office position based in our Albuquerque, NM facility.

Requirements

Bachelor's degree in Optical Engineering, Manufacturing Engineering, Mechanical Engineering with a focus in Optics (Optomechanical), Aerospace Engineering, Electrical Engineering, or a related technical field
10+ years of total relevant experience, of which 3+ years directly in the assembly, integration, alignment, and test of complex optical instruments, telescopes, laser systems, micro-electronics, high precision wafer fabrication, or space-based payloads
Experience leading a team of 4-6 Manufacturing Engineers and Sr. Technicians to develop the manufacturing area into a world class, ISO 5 or better Clean Room, Optical Payload Mfg. Environment
Hands-on experience with complex optomechanical assembly, precision alignment, integration, and bonding in cleanroom environments (ISO Class 5 or better)
Experience leveraging technical software for design, analysis, and test (e.g., Zemax, MATLAB, Python, LabView and/or C/C++)
Expertise in reading technical drawings and using SolidWorks or equivalent CAD software to develop tooling and fixtures
Experience defining and implementing manufacturing processes in a production environment, including New Product Introduction (NPI) for high-reliability systems
Solid interpersonal skills and a collaborative, hands-on attitude for working effectively with cross-functional, multi-disciplinary teams
Excellent attention to detail and technical writing skills for creating detailed procedures, test plans, and data summaries

Nice To Haves

Experience with space-qualified optical systems, laser communications, directed energy optics, fiber optics, and/or hyperspectral/multispectral imaging payloads
Experience implementing successful continuous improvement methodologies (e.g., Lean, Six Sigma) in high-reliability manufacturing
Familiarity with Manufacturing Execution System (MES) and Product Lifecycle Management (PLM) software
Experience across the space flight program lifecycle (design through on-orbit operations and qualification)
Knowledge of MIL-STD, NASA, or DoD standards for space hardware
Additional education or certifications in relevant engineering or scientific fields
Clearance Level Top Secret

Responsibilities

Lead a team of highly motivated Manufacturing Engineers and Sr. Technicians.
Support the Assembly, Integration, and Test (AI&T) of optical payloads and space-qualified systems, including laser communication terminals and imaging/stabilization hardware
Develop/document optical assembly procedures and work instructions, including precise metrology, alignment (warm/cold), bonding, and performance testing in simulated space conditions
Design, develop, and implement mechanical/electrical tooling, fixtures, and Ground Support Equipment (GSE) for optical assembly and test in cleanroom environments
Perform analysis of measured data for alignment, calibration, characterization, and environmental qualification, monitor production metrics and yield
Drive timely resolution of non-conformances (NCRs), conduct root cause analysis, implement corrective actions, and lead continuous improvement initiatives
Provide critical Design for Manufacturability (DFM) and Design for Assembly (DFA) feedback to optical, mechanical, and systems design teams
Provide technical oversight for external vendors and suppliers involved in optical component fabrication, coatings, and assembly
Participate in training production technicians to transition manufacturing lines from R&D/prototyping to scaled production
Recommend facilities, capital equipment, and process improvements to scale space-qualified manufacturing operations