Active Alignment & NPI Process Development Engineer
Core
Develop, characterize, qualify, and transfer optical alignment processes for photonic devices from prototype through NPI and volume manufacturing.
Role type
Senior IC process development engineer (optical active alignment)
Builds
Photonic engines, chip-to-chip optical interconnects, and scalable photonic solutions for AI supercomputing
Domain
Photonics / AI Infrastructure / Semiconductor Manufacturing
Deliverable
production ML models | product features | dashboards & analysis | research | client delivery | infrastructure | physical/clinical work
Required skills
optical active alignment process development, epoxy dispensing and curing, DOE and statistical process control, root-cause analysis, process capability analysis (Cp/Cpk, GR&R), fixture and tooling development, alignment algorithm development, equipment buyoff and qualification, manufacturing transfer, DFM/DFA review
Preferred skills
experience with FAU, lenses, isolators, PICs, PD, laser components, motion stages, controllers, optical power meters, laser sources, cameras, sensors, precision mechanical systems
Technologies
optical active alignment equipment, motion stages, controllers, optical power meters, laser sources, cameras, sensors, precision mechanical systems, epoxy dispensing systems, UV curing systems, thermal curing systems
Responsibilities
Lead manufacturing process development for new photonic products from prototype 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; 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
Seniority
Senior, hands-on IC