Active Alignment & NPI Process Development Engineer

About the role

Lumilens, a well-funded startup building the photonics infrastructure for AI supercomputing, is looking for an experienced Active Alignment Process Engineer. You will develop, characterize, qualify and transfer optical alignment processes from product development through NPI and volume manufacturing, and handle equipment buyoff and qualification, as well as epoxy dispensing and curing processes.

Key responsibilities

• Lead manufacturing process development for new photonic products from prototype and engineering builds through NPI qualification and volume production.
• Develop and optimize optical assembly processes including active and passive alignment, epoxy dispensing, curing, optical coupling and related assembly steps.
• Define critical process parameters, critical-to-quality characteristics, process windows, acceptance criteria and manufacturing specifications.
• Plan and run DOE, process characterization, tolerance studies and process optimization; evaluate yield, Cp/Cpk, GR&R and other metrics.
• Support prototype, EVT/DVT/PVT, pilot, qualification and production ramp builds, and perform root-cause analysis on NPI failures and yield excursions.
• Drive yield improvement, cycle-time reduction, process simplification and cost reduction.
• Maintain process documentation such as specifications, work instructions, SOPs, PFMEA, Control Plans and qualification reports, and support DFM/DFA reviews.
• Lead manufacturing process transfer to internal factories, suppliers or contract manufacturers and set up process controls after release.

Required profile

• Bachelor's degree or higher in Engineering, Physics, Optics, Photonics, Mechanical or Electrical Engineering or a related field.
• Minimum 5 years of relevant experience with optical active alignment for transceivers or related photonic devices, or in a related NPI/process development environment.
• Hands-on experience developing and optimizing optical active alignment processes, and with equipment buyoff, qualification and production deployment.
• Demonstrated experience in NPI process development, process characterization, qualification, manufacturing transfer and production ramp.

Required skills

• Familiarity with optical components such as FAU, lenses, isolators, PICs, PD and lasers.
• Knowledge of motion stages, controllers, optical power meters, laser sources, cameras, sensors and precision mechanical systems.
• Experience with alignment algorithms and automated alignment sequences.
• Knowledge of epoxy dispensing, adhesive bonding, UV and thermal curing, and of DOE, SPC, Cp/Cpk, GR&R and yield analysis.
• Familiarity with PFMEA, Control Plans, SOPs and work instructions.
• Strong troubleshooting, analytical and problem-solving skills, and ability to work across R&D, manufacturing, equipment suppliers, quality teams and contract manufacturers.