Responsibilities:The Senior Development Engineer will be a specialist in ultra precision diamond turning with hands-on experience operating, programming, and optimizing multi-axis diamond turning machines. Experience with 5-axis ultra-precision machining systems is strongly preferred.
The successful candidate will develop and validate manufacturing processes for high-precision optical and mechanical components, support customer applications, conduct machine demonstrations and acceptance trials, and provide technical leadership throughout the application lifecycle. This role requires a strong understanding of single-point diamond turning, freeform machining, precision metrology, machine dynamics, tooling, and environmental process control.
Key accountabilities and responsibilities for the Senior Development Engineer include but are not limited to:
- Develop, optimize, and document diamond-turning processes for spherical, aspheric, diffractive, off-axis, and freeform components.
- Program, set up, and operate multi-axis ultra-precision diamond-turning machines, preferably including 5-axis platforms.
- Select suitable machining strategies, tool geometry, workholding, process parameters, and compensation methods.
- Translate optical or mechanical designs into manufacturable processes using CAD/CAM and machine-specific programming systems.
- Conduct process feasibility studies, cycle-time estimates, and technical risk assessments.
- Achieve demanding dimensional, form, surface-finish, and optical-performance requirements.
- Diagnose and resolve issues involving tool wear, vibration, thermal drift, servo performance, surface defects, alignment, and workholding.
- Use metrology data to characterize errors and implement corrective or iterative machining strategies.
- Provide on-site and remote technical support, employee training, and process-development assistance to customers and partner sites.
- Collaborate with machine design, controls, software, service, sales, and product-development teams.
- Support the development of new machine capabilities, accessories, tooling solutions, and application software.
- Prepare technical reports, application notes, operating procedures, training materials, and customer presentations.
- Mentor junior applications engineers and establish best practices for ultra-precision machining.
- Maintain compliance with applicable quality, safety, export-control, and information-security requirements.
Requirements & Experience:- Due to the position's access to export-controlled technical data, candidates must qualify as a "U.S. person" under applicable U.S. export-control regulations. This includes U.S. citizens and lawful permanent residents.
- Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Optical Engineering, Precision Engineering, Mechatronics, or a related discipline. Equivalent advanced technical experience may be considered.
- Typically, 7 or more years of relevant experience in ultra-precision machining, diamond turning, precision optics manufacturing, or a closely related field.
- Demonstrated hands-on experience with multi-axis diamond-turning machines.
- Strong knowledge of single-point diamond turning and ultra-precision process development.
- Experience machining materials such as aluminum alloys, crystals, copper, nickel-phosphorus-plated substrates, optical polymers or other diamond-machinable materials.
- Ability to interpret complex engineering drawings, geometric dimensioning and tolerancing, optical prescriptions, and surface specifications.
- Working knowledge of precision metrology, including several of the following:
- Interferometry
- Profilometry
- Form measurement
- Surface-roughness measurement
- Coordinate measuring machines
- Optical alignment and inspection
- Experience diagnosing surface-finish and form-error problems using metrology and process data.
- Understanding of machine kinematics, servo systems, thermal stability, vibration control, spindle performance, and error compensation.
- Experience with CAD/CAM software, CNC programming, and machine-control interfaces.
- Strong analytical, troubleshooting, documentation, and customer-facing communication skills.
- Ability to work independently and lead technically complex application projects.
Ability and willingness to travel and work periodically to customer or partner facilities
Characteristics:- Ultra-precision machining expertise: Demonstrates deep knowledge of single-point diamond turning, machine-tool capabilities, cutting tools, material behavior, surface generation, and the factors that influence optical form and surface finish.
- Advanced technical aptitude: Quickly understands complex technical concepts, applies engineering principles to unfamiliar problems, and learns new technologies, materials, equipment, and processes.
- Process development mindset: Enjoys developing new machining methods, testing unconventional approaches, and establishing reliable processes for challenging components or materials.
- Technical adaptability: Adjusts approaches as material properties, part geometry, equipment capabilities, or customer requirements change. Is comfortable working through uncertainty when developing new capabilities.
- Analytical problem-solving: Breaks complex technical challenges into manageable components, evaluates evidence, and develops logical, technically sound solutions.
- Root-cause thinking: Investigates the underlying causes of machining defects, process instability, tool wear, and inconsistent results rather than treating symptoms.
- Curiosity and experimentation: Asks questions, challenges assumptions, and uses structured experiments to understand why a process behaves as it does.
- Creativity and innovation: Generates new approaches to machining, tooling, programming, process control, and manufacturing challenges that improve capability or enable previously impractical solutions.
- Ownership and accountability: Takes responsibility for technical challenges and outcomes, follows problems through to resolution, and communicates risks or setbacks early.
- Sound engineering judgment: Makes decisions based on technical evidence, risk, customer requirements, and practical manufacturing constraints. Knows when to proceed independently and when additional expertise or approval is needed.
- Technical leadership: Provides technical direction, establishes sound engineering approaches, and guides others through complex machining or development challenges without needing formal management authority.
- Knowledge sharing and mentoring: Transfers expertise to engineers, programmers, machinists, and technicians; explains the reasoning behind technical decisions; and helps build organizational capability.
- Cross-functional collaboration: Works constructively with Manufacturing, Quality, Metrology, Engineering, and Operations to develop solutions that satisfy technical requirements and can be implemented in production.
- Clear technical communication: Explains complex engineering concepts, experimental findings, risks, and recommendations in ways that are understandable and useful to different audiences.
Salary Range - $100-150k
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