Optical System Design Lead

Xscape Photonics Inc; Santa Clara (CA); On-site; USD 120,000 - 180,000; Full time

Job summary

Xscape Photonics Inc in Santa Clara, CA is seeking an experienced NPI Engineer to own the manufacturing process development for state-of-the-art photonic products. This hands-on role bridges design and high-volume production, focusing on Silicon Photonics devices and scalable, cost-efficient processes.

You will develop robust assembly methods, transfer processes to contract manufacturers, and drive yield improvements through SPC/DOE while partnering with design and manufacturing teams to ensure

Qualifications

• Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Materials Science, Physics, or related technical field.
• 5+ years of experience in a process engineering or NPI role within the semiconductor, electronics, or photonics packaging industry.
• Hands-on experience developing and sustaining key assembly processes such as precision die bonding, wire bonding, optical alignment and wafer level processing.
• Demonstrated experience working with Silicon Photonics devices and their associated assembly and packaging processes.
• Proficiency in applying Statistical Process Control (SPC) and Design of Experiments (DOE) to solve manufacturing problems.

Responsibilities

• Lead the hands-on development, characterization, and optimization of core assembly processes, including precision die bonding, wire bonding, and active/passive optical alignment.
• Design, develop, and qualify manufacturing processes and equipment with a clear path to ramping to high-volume manufacturing (HVM). Define equipment specifications and drive the design of custom fixtures and tooling.
• Implement and manage SPC for critical process parameters. Use statistical methods (DOE, Cp/Cpk analysis) to monitor process health, drive yield improvements, and ensure manufacturability.
• Serve as the subject matter expert for Silicon Photonics device assembly, including fiber attach, thermal management, and high-density interconnects.
• Work closely with the design engineering team to provide critical DFM feedback, ensuring products are designed for robust, high-yield manufacturing.
• Drive root‑cause analysis for yield excursions and process failures. Implement corrective and preventative actions to achieve yield targets.
• Create documentation and lead the technical transfer of new products and processes to CM partners.

Skills

Die bonding

Wire bonding

Optical alignment

SPC

DOE

CM transfer

Education

Bachelors in Engineering/Physics

Tools

JMP

Minitab

Job description

NPI Engineer

We are seeking a highly skilled and motivated Process Engineering expert in Photonics to own the manufacturing process development for our state-of-the-art photonic products. This is a hands-on role responsible for bridging the gap between design and high-volume production.

You will be a technical expert for our assembly and packaging processes, with a special focus on Silicon Photonics devices. Your primary mission will be to develop robust, scalable, and cost-effective manufacturing processes and transfer them successfully to our production partners. If you are a data-driven engineer who thrives on solving complex manufacturing challenges, this is the role for you.

What You'll Do (Responsibilities)

• Process Development & Optimization: Lead the hands-on development, characterization, and optimization of core assembly processes, including precision die bonding, wire bonding, and active/passive optical alignment.
• High-Volume Scalability: Design, develop, and qualify manufacturing processes and equipment with a clear path to ramping to high-volume manufacturing (HVM). Define equipment specifications and drive the design of custom fixtures and tooling.
• Statistical Process Control (SPC): Implement and manage SPC for critical process parameters. Use statistical methods (DOE, Cp/Cpk analysis) to monitor process health, drive yield improvements, and ensure manufacturability.
• Silicon Photonics Assembly: Serve as the subject matter expert for the unique challenges associated with Silicon Photonics device assembly, including fiber attach, thermal management, and high-density interconnects.
• Design for Manufacturability (DFM): Work closely with the design engineering team to provide critical DFM feedback, ensuring that new products are designed for robust, high-yield manufacturing.
• Yield Improvement: Drive root‑cause analysis for yield excursions and process failures. Implement robust corrective and preventative actions to achieve and exceed yield targets.
• Manufacturing Transfer: Create comprehensive documentation (work instructions, control plans, PFMEAs) and lead the technical transfer of new products and processes to our contract manufacturing (CM) partners.

Minimum Qualifications

What You'll Bring (Qualifications)

• Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Materials Science, Physics, or a related technical field.
• 5+ years of experience in a process engineering or NPI role within the semiconductor, electronics, or photonics packaging industry.
• Direct, hands‑on experience developing and sustaining key assembly processes such as precision die bonding, wire bonding, optical alignment and wafer level processing.
• Demonstrated experience working with Silicon Photonics devices and their associated assembly and packaging processes.
• Proficiency in applying Statistical Process Control (SPC) and Design of Experiments (DOE) to solve manufacturing problems.

Preferred Qualifications

• Master’s degree or PhD in a relevant technical discipline.
• A proven track record of successfully developing manufacturing processes and ramping them into high-volume manufacturing.
• Deep expertise in materials (e.g., epoxies, solders) and characterization techniques used in microelectronic and photonic assembly.
• Experience specifying, sourcing, and qualifying automated or semi‑automated manufacturing equipment.
• Experience with statistical analysis software such as JMP or Minitab.
• Experience working with and managing offshore contract manufacturers (CMs).
• Strong problem‑solving skills and a hands‑on, data‑driven approach.