Optical Fabrication Engineer
About The Position
Bond Optics is seeking an experienced Optical Fabrication Engineer to join our Lebanon, NH facility as a senior technical contributor to our precision optics production team. This role is the backbone of our conventional fabrication capability the processes that transform raw optical blanks into finished flats, spheres, prisms, and wedges meeting the most demanding defense, aerospace, and scientific program requirements. Unlike a CNC-centric role, this position is built around the physics and craftsmanship of conventional optical fabrication: loose-abrasive grinding, pitch polishing, double-sided lapping and polishing, prism work, and the full measurement and process control framework that supports them. The successful candidate is a deeply skilled fabricator who understands why processes work not just how to run them and who can diagnose yield and quality issues from first principles. This engineer will own process development, yield improvement, and technical problem-solving across the conventional fab floor, work directly with metrology and engineering to qualify new part families, and serve as a senior technical mentor to our optical fabrication technicians. Grinding & Polishing Loose-abrasive grinding, pitch polishing, polyurethane pad polishing, SSD management, Double-Sided Lapping & Polishing SpeedFam 20B, GlassMaster 720 planetary kinematics, carrier design, pressure/velocity control. Prism & Complex Geometry Angle fabrication, pitch buttons, optical contacting, multi-element assemblies, wedge work.
Requirements
- 5+ years of hands-on precision optical fabrication experience in a defense, aerospace, or scientific optics production environment.
- Demonstrated expertise in conventional (non-CNC) fabrication processes: loose-abrasive grinding, pitch polishing, double-sided lapping/polishing, and prism work.
- Proven ability to independently develop and qualify fabrication processes from raw blank through finished component.
- Track record of solving complex yield, figure, or finish problems through first-principles analysis.
- Deep working knowledge of optical fabrication physics: Preston equation, Hertzian contact, SSD mechanics, and pitch rheology.
- Expert-level pitch polishing tool preparation, lap conditioning, hand figuring, and full-aperture convergence.
- Double-sided lapping/polishing experience on SpeedFam, GlassMaster, Lapmaster, or equivalent planetary machines.
- Prism fabrication experience including angle control, blocking, and arc-second measurement.
- Proficient with Zygo interferometers and MetroPro; able to interpret Zernike, PSD, and slope data.
- Able to read and interpret optical drawings per MIL-PRF-13830B and ISO 10110 (all applicable parts).
- Solid grasp of ASME Y14.5 GD&T as applied to optical components.
- Bachelor's degree in Optical Engineering, Physics, Materials Science, Mechanical Engineering, or a related technical field, with 5+ years of hands-on precision optical fabrication experience; OR
- 10+ years of directly applicable precision optical fabrication experience in lieu of a degree, with demonstrated expertise across grinding, polishing, metrology, and complex geometry work.
Nice To Haves
- Experience with continuous polishers (CP) up to 96" diameter.
- MetroScript (Zygo OMP-0399P) scripting capability for automated measurement and data analysis.
- Familiarity with QED MRF (magnetorheological finishing), ion beam figuring, or other sub-aperture deterministic processes as complements to conventional work.
- Experience with optical glass, such as N-BK7, or ceramic materials, such as Zerodur®. Experience with crystalline and IR materials (ZnS, Ge, Si, ZnSe, sapphire).
- Familiarity with AS9100 quality management system requirements.
- Working knowledge of ERP/MRP systems for production routing and travelers.
- Exposure to acid etching, MRF, or other post-polish surface treatments.
Responsibilities
- Develop, qualify, and document loose-abrasive grinding and pitch-polishing processes for flats, spheres, prisms, and wedges across optical glasses, fused silica, calcium fluoride, and crystalline materials.
- Own pitch selection and management for the full fabrication pitch range (Gugolz #55–#82, Universal Photonics CP #55–#82); specify blends, flow control, channel geometry, and temperature regimes for each application.
- Control and troubleshoot cerium oxide and diamond slurry chemistry, concentration, pH, and contamination for consistent removal rate and surface quality.
- Diagnose and mitigate subsurface damage (SSD); establish grind-to-polish transition strategies that minimize polishing time while meeting figure and finish requirements.
- Perform CP lap conditioning and pad management; drive figure convergence on 12"–96" continuous polishers.
- Own process development and optimization for SpeedFam 22B, OptiPro GlassMaster 720, and equivalent equipment.
- Design and qualify carriers for new part geometries; specify pocket placement, eccentricity, and pressure distribution to achieve target figure and parallelism.
- Apply planetary kinematics speed ratio (k), relative velocity, and Preston equation fundamentals to predict and control removal rate and uniformity.
- Troubleshoot common DSP/DSL failure modes: center-to-edge non-uniformity, carrier wear, pad glazing, part chipping, and carrier-induced scratching.
- Lead prism angle fabrication including right-angle, Dove, Penta, Schmidt, and roof prisms; control pyramidal error, angle tolerance, and 90° squareness to arc-second levels.
- Specify and execute wax blocking, pitch button blocking, and array blocking strategies for prism and wedge production.
- Apply blocking-plate wedge analysis to predict and control cross-wedge and thickness variation in array-blocked components.
- Develop multi-element assembly and de-blocking procedures that protect finished surfaces.
- Operate Zygo GPI/Fizeau and NewView interferometers; interpret MetroPro / MX output including Zernike decomposition, PV/RMS figure, slope, and PSD/MSF analysis.
- Use MetroScript (OMP-0399P) for automated measurement routines, including the center-phase-array method for data centering and translation on masked apertures.
- Specify and apply MIL-PRF-13830B and ISO 10110 surface quality, figure, wedge, and centration requirements on engineering drawings.
- Use ZEISS CALYPSO CMM, Prism Master, autocollimators, and mechanical inspection tools to qualify dimensional and angular tolerances.
- Partner with Quality to drive FAI (AS9102), Gage R&R, and corrective action for fabrication yield issues.
- Author and maintain work instructions, SOPs, and process travelers for conventional fabrication operations in ERP system.
- Lead root-cause analysis on yield loss, scrap, and rework; implement preventive measures with measurable impact.
- Evaluate and qualify new equipment, tooling, and consumables (pitch, abrasives, carriers, blocking materials).
- Mentor Optical Fabrication Technicians I–III; support skills development, competency assessments, and training.
- Collaborate with operations on producibility reviews and design-for-fabrication feedback during quoting and program kickoff.
Benefits
- Performance-based annual bonus opportunity.
- Comprehensive health, dental, and vision insurance.
- 401(k) with company contribution.
- Paid time off, company holidays, and sick leave.
- Life and disability insurance.
- Continuing education and professional development support.
- Relocation assistance available for qualified candidates.
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What This Job Offers
Job Type
Full-time
Career Level
Mid Level
Number of Employees
1-10 employees
