Lead Process EngineerLos Angeles, CA (in-person)
PurposeWe are seeking a Lead Processing Engineer who can own the end-to-end process flow that turns early prototypes into reliable, repeatable, and scalable conductor products. This is a hands-on leadership role spanning feedstock preparation, build recipes, carbon infusion or growth steps, post-processing, QA controls, documentation, and pilot readiness.
The roleThis role reports directly to the CEOEnd-to-end process ownership- Own Arcturus' R&D-to-pilot process flow, from feedstock handling and preparation through LPBF/DED processing, carbon infusion or growth steps, post-processing, finishing, inspection, and sample release
- Translate early technical learnings into repeatable process recipes, standard work, process flow diagrams, and controlled operating procedures
- Define critical process parameters and critical quality attributes across each step of the conductor manufacturing flow
- Establish pragmatic process controls that preserve electrical conductivity, thermal performance, mechanical integrity, and nanomaterial stability
- Partner with additive manufacturing and nanomaterials leads to ensure each process step is technically sound, measurable, and scalable
Process development and optimization- Build and run a disciplined design of experiments (DOE) cadence to expand process windows, improve repeatability, increase yield, and reduce cycle time
- Develop process maps that connect feedstock, atmosphere, laser parameters, thermal history, growth or infusion conditions, and post-processing to final material performance
- Identify bottlenecks, failure modes, and sources of variation, then drive practical solutions that improve consistency and throughput
- Use data analysis, structured root-cause methods, and hands-on experimentation to troubleshoot failed builds, inconsistent samples, or missed performance targets
- Help decide when a process is ready to move from exploratory R&D to controlled development and eventually pilot production
Quality, documentation, and pilot readiness- Build startup-appropriate quality systems, including control plans, lot tracking, travelers, acceptance criteria, test plans, and traceable build records
- Write and maintain process specifications, work instructions, checklists, and documentation that technicians and engineers can actually use
- Define sample release criteria for internal testing, third-party validation, customer demos, and pilot programs
- Support process qualification plans for conductor materials, printed parts, and wire forms as Arcturus moves toward external validation
- Track process health metrics such as yield, repeatability, build success rate, cycle time, material usage, and throughput
Cross-functional leadership- Partner closely with nanomaterials, additive manufacturing, characterization, mechanical, and product engineering to tie process variables to conductivity, thermal performance, mechanical properties, and reliability
- Own process-facing vendor and partner relationships, including equipment suppliers, metrology providers, external test labs, and validation partners
- Help translate characterization results into material specs, process windows, acceptance criteria, and clear technical decisions
- Hire and lead process engineers, technicians, and operators as the team scales
- Contribute to invention disclosures, patent strategy, and internal technical documentation with a high bar for rigor and clarity
Basic qualifications- BS, MS, or PhD in materials science, metallurgical engineering, chemical engineering, mechanical engineering, manufacturing engineering, physics, or a related field
- 8+ years of hands-on process engineering, manufacturing engineering, materials processing, or advanced process development experience
- Deep experience developing and scaling complex manufacturing processes in a hardware, materials, or advanced manufacturing environment
- Strong understanding of process-structure-property relationships in metals, metal matrix composites, or other high-performance material systems
- Experience using DOE, statistical analysis, process controls, and structured root-cause methods to improve yield, repeatability, and performance
- Strong scientific and technical writing skills, including clear documentation of process development, test plans, specifications, and invention disclosures
Preferred qualifications- Experience with LPBF, DED, laser processing, welding, CVD/LCVD/LACVD, high-temperature gas processes, or related advanced manufacturing methods
- Experience with aluminum, copper, conductor materials, or metal matrix composites
- Direct experience with carbon nanomaterial-metal composites, covetics, graphene, carbon nanotubes, or carbon-metal interface engineering
- Experience building process controls for new materials, new equipment, or first-of-its-kind manufacturing workflows
- Familiarity with conductor, cable, automotive, aerospace, energy, or utility qualification pathways
- Experience working in a startup or fast-paced R&D-to-manufacturing environment
What we offer- Competitive cash compensation and meaningful equity
- Scientific ownership with direct product impact
- The chance to define the playbook for nanomaterial-enhanced conductors
- Relocation support for candidates moving from outside the Los Angeles area
- Visa sponsorship for highly qualified candidates (H-1B transfers, F-1, or STEM OTP)
