Senior Laser Process Engineer

About Us

Founded in 2015 to develop the world’s first industrially scalable laser metal additive manufacturing solution, VulcanForms is reshaping how the world manufactures critical products. We build and operate advanced digital infrastructure that enables innovation, accelerates growth, and supports sustainability across aerospace, defense, medical, and other essential industries. Through our vertically integrated capabilities, including scalable additive manufacturing and precision machining, we deliver true end-to-end production at scale by combining cutting-edge technology with a foundation of proven industrial craftsmanship. Our team brings deep expertise in manufacturing, materials science, software, automation, and operations, united by a shared commitment to quality, curiosity, and accountability. We foster an inclusive culture where people take ownership, solve meaningful problems, and continuously learn, because we believe diverse perspectives lead to better outcomes.

Job Purpose

As the Senior Laser Process Engineer, you will serve as the primary technical owner and process expert for the advanced laser marking and industrial traceability cells powering VulcanForms’ newest manufacturing program launch. In this execution-focused role, you will independently bridge the gap between initial hardware integration and stable factory-floor deployment. You will own the installation, validation (IQ/OQ), optical calibration, and statistical recipe development for our precision laser systems.

Key Responsibilities

• Own the hands-on commissioning and verification of advanced industrial laser systems (including Fiber, UV, Green, and ultra-fast Picosecond/Femtosecond arrays). Draft and execute comprehensive Installation Qualification (IQ) and Operational Qualification (OQ) protocols covering safety interlocks, optical alignment, and utility hookups.
• Ensure absolute processing repeatability by verifying system power stability, focal position, beam diameter, spot size, and scanner field distortion. Conduct routine galvo scanner calibrations and validate vision-alignment systems to minimize placement drift.
• Develop robust laser-marking recipes from scratch for diverse materials and product configurations. Design structured engineering experiments (DOE) to manipulate core process variables—including laser power, pulse width, frequency, scan speed, hatch spacing, and focal offset—to optimize marking contrast and minimize Heat-Affected Zones (HAZ).
• Establish quality acceptance criteria for marked components. Utilize optical microscopes, surface profilometers, and specialized vision verification systems to audit marking depth, contrast, and barcode readability grades. Ensure flawless execution of serialization architectures (UID, UDI, Data Matrix codes).
• Partner closely with working-level Automation, Robotics, and Software teams to integrate standalone laser marking cells into fully automated production lines. Assist in configuring PLC handshakes, recipe management systems, and sensor telemetry to feed critical manufacturing data into enterprise platforms (MES/ERP).
• Own the transfer of calibrated processes from the validation phase over to 24/7 manufacturing operations. Define, monitor, and improve cell-level equipment KPIs (OEE, Uptime, MTBF) and process/production KPIs (First-Pass Yield, Barcode Grade Consistency, Cycle Time, Process Capability Cp/Cpk).
• Act as the technical escalation point for the floor to resolve quality defects (e.g., poor contrast, burn marks, unreadable codes) and equipment faults (e.g., optical contamination, beam misalignment). Author comprehensive Standard Operating Procedures (SOPs), maintenance schedules, and operator training frameworks.

Qualifications

• 5 years of hands-on experience in laser material processing, laser marking, or laser micro-machining within a high-volume precision manufacturing environment.
• Direct experience setting up, operating, and aligning industrial laser systems (Fiber, UV, or CO₂) utilizing galvo scanners, F-theta optics, and beam delivery systems.
• Documented track record executing formal IQ/OQ/PQ protocols and utilizing vision inspection or barcode verification systems to gauge edge quality and contrast.
• Proven ability to run structured process window characterizations and analyze process capability utilizing statistical software (Minitab, JMP, or equivalent data tools).
• Bachelor’s or Master’s degree in Mechanical Engineering, Optical Engineering, Manufacturing Engineering, Materials Science, Physics, or a highly related technical discipline.
• Excellent communication skills with a demonstrated ability to collaborate cross-functionally across mechanical, electrical, and quality engineering cohorts to drive project milestones.

Preferred Qualifications

• Experience with high-precision laser marking software and controller interfaces (e.g., Scanlab, EZCAD, LightBurn, or proprietary OEM software environments).
• Background working within validation-heavy or highly regulated traceability sectors such as Semiconductor component marking, Electronics/PCB manufacturing, Medical Device UDI printing, or Automotive cell traceability.
• Familiarity with industrial automation protocols, fieldbus networks, and integrating third-party equipment with programmable logic controllers (PLCs).

VulcanForms offers a competitive salary and equity package. Actual compensation is based on factors such as the candidate's skills, qualifications, and experience. In addition, VulcanForms provides comprehensive benefits including medical, dental, vision, and life insurance; generous paid time off; and a 401(k) plan with company match.

The annual base salary range for this position is $106,000 to $146,000.