The Process Development Engineer is responsible for developing new and/or expanding current assembly process platforms and transferring them to manufacturing. He or she must be a multitasking team player and able to interface with multiple engineering groups. The person should have hands-on experience with process development and be well versed in mechanical engineering or materials science as well as automated equipment in a high-volume manufacturing environment. He or she should be familiar with automated equipment, such as but not limited to, optical device alignment, pick and place, fiber attach, flip chip assembly, thermocompression bonding, flex circuit interconnect technologies such as u-flex, or pick and place machines with adhesive dispensing capability; Design of Experiments (DOE), Failure Mode Effects Analysis (FME A), in innovative data reduction, and statistical analysis. Experience working in a cleanroom environment is a plus. Candidate must be able to precisely document and communicate assembly process details for successful transfer of assigned processes to manufacturing.
Develop, characterize, and qualify manufacturing processes from concept through development and transfer to manufacturing, including specifying and procuring required equipment, process flow, process development/verification, and qualification plan
Design, execute, and analyze experiments through DOE and statistical techniques using statistical tools
Design tooling and fixturing for assigned processes.
Set up and conduct process checks and complete process documentation for assigned processes to be successfully transitioned from Development into Manufacturing
Lead and perform Failure Mode Analysis (FMA) techniques as part of process characterization and Root Cause Corrective Action (RCCA) plans
Train technicians and oversee equipment calibration and maintenance scheduling
Develop all required documentation for processes that transfer to manufacturing
BS degree in Engineering with 3 to 6 years of experience or MS degree in Engineering, 0 to 4 years of experience
Demonstrated ability to independently initiate, prioritize, and drive projects to completion
Ability to effectively communicate ideas, concepts, and results to both highly technical and non-technical co-workers within cross-functional teams
Ability to function independently as well as in a team environment
Hands-on experience with opto-electronic module assembly processes including optical device alignment, free space optics, fiber attach of fiber pig-tails, flex circuit interconnect, vacuum solder chambers, hot bar solder equipment, flip chip processing, pick and place, adhesive dispense and thermal cycling
Proven experience in design and process development functions
Highly motivated, team player adept at working and meeting goals cross-functionally
Experience in high volume manufacturing a plus
Excellent written and verbal communication skills combined with a high attention to detail
Ability to use CAD tools such as Creo and/or SolidWorks
Working knowledge of mechanical drawings and dimensional tolerances
Understanding of optics is a plus
Ability to maintain a clean and safe working environment
Job Category Applied R&D
Posting Date 08/07/2026
Degree Level Bachelor's degree
Job Schedule Full time
Job Type Experienced
Job Identification 39125
Role Type Individual contributor
Salary Range USD 88K- 163K *Plus potential variable/compensation for eligible roles
Experience level Experienced
Locations 7360 Windsor Drive, Allentown, Pennsylvania, 18106-9318, US (Onsite)
Regular or Temporary Regular
7360 Windsor Drive, Allentown, Pennsylvania, 18106-9318, US
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