Senior Manufacturing Engineer - Space Technologies

into repeatable production processes. The engineer will lead process development and continuous improvement, support research and development and new product introduction, resolve complex production issues, and mentor engineers and manufacturing personnel while improving quality, yield, cost, safety, and delivery.

Position

• ◆Develop, document, validate, and sustain assembly, integration, alignment, and test processes for space optical systems, precision optomechanical assemblies, and fast steering mirrors.
• ◆Lead manufacturing readiness activities from prototype development through design transfer, qualification builds, and production transition; identify process maturity gaps and implement closure plans.
• ◆Review designs for manufacturability, assembly, alignment access, inspection, testability, serviceability, and cost; address tolerance stacks, datum strategies, and sensitivity to handling and assembly variation.
• ◆Establish methods for handling, cleaning, protecting, packaging, and storing delicate optics and coated surfaces; define contamination, foreign object debris (FOD), and electrostatic discharge (ESD) controls appropriate to the hardware.
• ◆Develop controlled bonding and curing processes, including surface preparation, adhesive mixing and dispensing, bond-line control, fixturing, shimming, cure parameters, and witness coupons or other verification methods as required.
• ◆Develop FSM assembly processes for mirrors, mounts, flexures, actuators, coils, sensors, wiring, and cables; control polarity, cable routing, keep-out zones, flexure protection, and repeated handling during adjustment.
• ◆Partner with Optical and Test Engineering to establish alignment sequences, metrology setups, reference datums, adjustment methods, and acceptance criteria for optical and electromechanical performance.
• ◆Develop repeatable measurement and test methods for applicable requirements, such as mirror flatness, surface figure, wavefront error, boresight, line-of-sight stability, range of motion, pointing accuracy, repeatability, and dynamic response.
• ◆Create and maintain controlled work instructions, process specifications, standard operating procedures, process flow diagrams, travelers, assembly aids, bills of material, routings, and tooling requirements.
• ◆Design or coordinate precision fixtures, alignment tooling, optical handling aids, gauges, and test equipment; ensure production aids protect hardware and support repeatable assembly and inspection.
• ◆Support equipment selection, installation and operational qualification, performance qualification where required, calibration, measurement-system assessment, and preventive maintenance planning.
• ◆Establish process parameters, in-process inspection points, acceptance criteria, traceability requirements, and production controls; maintain process failure mode and effects analyses (PFMEAs) and associated control plans.
• ◆Investigate nonconformances, optical performance degradation, bond failures, alignment drift, yield losses, and process escapes; lead structured root-cause analysis and verify corrective-action effectiveness.
• ◆Analyze process and test data to identify variation, constraints, rework drivers, and capacity needs; apply Lean Manufacturing, Six Sigma, and other appropriate improvement methods.
• ◆Support first article inspections, capability studies, process validation, qualification testing, and production readiness reviews; assess alignment and functional performance before and after environmental testing as required.
• ◆Partner with Quality Engineering on material review board activities, inspection methods, corrective actions, and disposition support; evaluate rework methods for effects on optical surfaces, bonds, and alignment.
• ◆Support supplier development and qualification of optics, coatings, precision-machined hardware, adhesives, electromechanical components, and outsourced processes; translate

into receiving and acceptance controls.

• ✓Assess manufacturing impacts of design, material, chemistry, tooling, software, and process changes; define supporting data, requalification needs, documentation updates, and implementation tasks.
• ✓Develop training using mock-ups, representative hardware, and practical demonstrations; mentor Manufacturing/Process Engineers I and II and train technicians in optical handling, assembly, alignment, and process discipline.
• ✓Participate in design reviews, risk assessments, production readiness reviews, and program reviews; communicate manufacturing risks, recovery plans, and readiness status.
• ✓Ensure manufacturing processes meet applicable engineering, quality, safety, environmental, and program requirements; support urgent production troubleshooting and perform other duties as assigned.

Basic

• ✓Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Optical Engineering, Electrical Engineering, Industrial Engineering, or a related technical field.
• ✓Typically 3–7 years of relevant manufacturing or process engineering experience, or an equivalent combination of education and experience.
• ✓Demonstrated experience developing and sustaining proc