The Senior Process Engineer will develop sealing processes for advanced optoelectronic packages (e.g., CPO, ELSFP). The position requires close collaboration with R&D and product design teams, manufacturing, suppliers, and customers to ensure product components meet stringent optical, mechanical, and Telcordia reliability requirements.
What You Will Do- Develop and implement processes to attach various components (e.g., TEC, housing, lid, fiber lens or discrete lenses)
- Own automated process development using die-attach tools (MRSI), including: process set up, alignment and recipes
- Design and implement solder hierarchies (e.g., AuSn, SAC, etc.) to support multiple reflows without reflow or voiding
- Develop hermetic lid-sealing process via electrical or laser welding, or soldering to seal ring
- Develop hermetic fiber-sealing process to housing (e.g., glass frit, Cerrocast) to achieve leak rate ( 5N)
- Partner with product and operation teams to ensure designs are compatible with manufacturable, high-yield assembly flows
- Define process windows, control plans, and critical-to-quality (CTQ) parameters
- Support component supplier selection and evaluation of: housing, lid, seal rings, fiber-feedthrough. Evaluate process capability and maturity
- Define and oversee component pre-qualification tests to ensure reliable designs (e.g., temperature cycling, damp heat resistance)
- Support failure analysis investigations and corrective actions for product related failures and manufacturing issue (e.g., solder defects (cracks, delamination)
- Drive corrective actions across materials, processes and supplier inputs
Who You Are (Basic Qualifications) - MS in Material Science, Mechanical Engineering, Physics, Optics, or a closely related field
- At least 10 years of industry R&D experience with solder/epoxy processes used for optoelectronic packages developed and transferred to manufacturing environments
- Hands-on experience with DOE, DFM, statistical tools for efficient optimization (e.g., Minitab or JMP)
- Expertise in solder hierarchy reflow applied to metalized surfaces and bare-glass surfaces
- Experience of process-attach issues (e.g., CTE mismatch, stress, adhesion, thermal limits, etc.)
- Experience with optical components (e.g., gratings, mirrors, lenses), stable attachment methods (e.g., epoxy and solder based)
- Expertise in component qualification methodologies (e.g., GR-468), and product reliability testing
- Experience with solder-process failures (e.g., cracks, intermetallics, solder fatigue) through failure mode analysis tools
- Experience with New Product Introduction (NPI) methodology: design, verification, qualification, release to manufacturing
- Strong communication skills with suppliers and cross-functional internal teams
For this role, we anticipate paying $160,000 - $250,000 per year. This role is eligible for variable pay, issued as a monetary bonus or in another form.
Hiring Philosophy All Koch companies value diversity of thought, perspectives, aptitudes, experiences, and backgrounds. We are Military Ready and Second Chance employers. Learn more about our hiring philosophy here .
Our Benefits Our goal is for each employee, and their families, to live fulfilling and healthy lives. We provide essential resources and support to build and maintain physical, financial, and emotional strength - focusing on overall wellbeing so you can focus on what matters most. Our benefits plan includes - medical, dental, vision, flexible spending and health savings accounts, life insurance, ADD, disability, retirement, paid vacation/time off, educational assistance, and may also include infertility assistance, paid parental leave and adoption assistance. Specific eligibility criteria is set by the applicable Summary Plan Description, policy or guideline and benefits may vary by geographic region. If you have questions on what benefits apply to you, please speak to your recruiter.
Additionally, everyone has individual work and personal needs. We seek to enable the best work environment that helps you and the business work together to produce superior results.
