Mechanical Engineer-Photonics

QCi•Bedford, MA

14h

About The Position

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.

Requirements

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.

Nice To Haves

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.

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.