Senior Laser Process Development Engineer

Location: Andover (CDP), MA
Salary: $100,000.00 USD Annually - $140,000.00 USD Annually
Description: Overview

We are seeking a highly skilled and driven Senior Laser Process Development Engineer to join our Manufacturing Engineering team. This role focuses on developing, implementing, and optimizing advanced laser-based manufacturing processes for next-generation power components. The ideal candidate will play a pivotal role in enhancing product performance, improving packaging technologies, and delivering scalable, cost-effective manufacturing solutions across high-impact industries such as industrial automation, hyperscale computing, AI, aerospace, defense, and automotive.
Key Responsibilities

• Collaborate with cross-functional teams to develop and implement advanced laser-based manufacturing processes
• Design and qualify precision laser equipment and packaging processes for semiconductor production
• Lead cost-reduction initiatives through process innovation and packaging enhancements
• Operate and maintain laser-based materials processing systems and procedures
• Interface with laser system manufacturers to evaluate and integrate emerging technologies
• Conduct experimental investigations to understand laser-material interactions and optimize process parameters
• Apply Six Sigma tools (e.g., PFMEA) and implement real-time SPC for process control
• Partner with NPI and design teams to improve yield and manufacturability
• Support readiness for IATF 16949 certification and automotive compliance
• Monitor yield and scrap trends; troubleshoot laser systems and recommend performance improvements

Required Qualifications

• Bachelor's degree in Physics, Applied Physics, Optics, Mechanical Engineering, Materials Science, or related field
• Minimum 5 years of experience in laser process development within R&D and high-volume manufacturing environments
• Strong understanding of laser-material interactions (e.g., ablation, melting, surface structuring, thermal effects)
• Proficiency in statistical methods (DOE, SPC, FMEA) and data analysis tools (e.g., JMP, Minitab, MATLAB, Python, SQL)
• Hands-on experience designing and executing laser processing experiments
• Proven ability to optimize laser recipes for precision manufacturing (e.g., trench geometry, heat-affected zones)
• Experience with CAD tools (e.g., SolidWorks, CircuitCAM) and laser programming software
• Knowledge of laser safety standards and procedures
• Excellent communication, documentation, and team collaboration skills
• Ability to manage multiple priorities in a fast-paced environment

Preferred Qualifications

• Master's degree in Materials Science or Engineering
• 5 years of industry experience in laser applications or laser-based manufacturing
• Proficiency in optical system design (beam delivery, shaping, focusing)
• Experience with laser scanners and scanner-based processing
• Strong foundation in laser physics and optics
• Background in simulation of laser-material interactions or optical systems
• Familiarity with micromachining applications (e.g., surface texturing, thin-film removal, micro-drilling)

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