Principal Manufacturing Engineer – Satellite Imaging Group

U.S. Fusion Energy; Southbridge (MA); On-site; USD 120,000 - 180,000; Full time

Job summary

U.S. Fusion Energy seeks a Principal Manufacturing Engineer for the AP50 Satellite Telescope Project.

You will lead process definition, prototype testing, and equipment development to enable first article and serial production of a 50 cm aperture camera designed for ground imaging from low Earth orbit. You will mentor engineers, collaborate with cross-functional teams, and champion quality, safety, and risk reduction.

Qualifications

• 10+ years in advanced optical systems manufacturing.
• Expert in optical component manufacturing and metrology.
• Proven cross-functional leadership and problem-solving.
• Experience with aerospace/defense optics is preferred.

Responsibilities

• Lead Manufacturing Readiness through all project phases.
• Collaborate with developers and operations for smooth transition to production.
• Develop, implement, and maintain SOPs and process documents.
• Conduct risk assessments and ensure safety/quality compliance.
• Oversee supplier interactions and component quality across supply chain.
• Mentor junior engineers and promote knowledge sharing.

Skills

Analytical thinking

Leadership

Cross-functional teamwork

Problem solving

Communication skills

Mentoring

Six Sigma

Education

Advanced degree in a related field

Tools

Optical metrology equipment

Interferometry techniques

Image analysis software

Aspheric and freeform metrology

Job description

Principal Manufacturing Engineer – Satellite Imaging Group

We are seeking an experienced and highly skilled Senior Process Engineer to join our AP50 Satellite Telescope Project Team. Your contributions will enable the successful product launch of our 50 cm aperture camera, designed for ground imaging from low Earth orbit. In this role, you will innovate and lead process definition and optimization initiatives. You will prototype and test methods, lead development of specialized manufacturing equipment, and provide technical expertise in the implementation of complex processes. You will work collaboratively with cross-functional teams, mentor junior engineers, create process documentation and champion quality, safety, and risk reduction improvements across the project.

Join the us as we advance state of the art in space-based imaging. Contribute your knowledge, work with an agile team of peers and evolve your skills to the next level as we launch our new advanced satellite camera.

Job Summary

We are seeking an experienced and highly skilled Senior Process Engineer to join our AP50 Satellite Telescope Project Team. Your contributions will enable the successful product launch of our 50 cm aperture camera, designed for ground imaging from low Earth orbit. In this role, you will innovate and lead process definition and optimization initiatives. You will prototype and test methods, lead development of specialized manufacturing equipment, and provide technical expertise in the implementation of complex processes. You will work collaboratively with cross-functional teams, mentor junior engineers, create process documentation and champion quality, safety, and risk reduction improvements across the project.

Role & Project Overview

The AP50 is a state-of-the-art silicon carbide satellite camera. The Principal Manufacturing Engineer will provide technical leadership in the development and execution of manufacturing methods required for first article and serial production of the new camera system. Key materials like Silicon Carbide (SiC) are integral to the project.

Manufacturing activities will focus on the fabrication of SiC optical and structural components, polishing mirror optical surfaces, and assembly/testing of the optical telescope. The Principal Manufacturing Engineer will be responsible for identifying, developing, and implementing technologies, tooling, and metrology processes that meet telescope performance and schedule requirements. You will also work closely with external suppliers and support vendor selection, technical requirements, and acceptance tests.

A key responsibility of this role will be the innovation and qualification of manufacturing methods and processes to ensure the successful achievement of design outcomes. You will lead process testing and prototyping in a fast-paced, agile environment. Wherever planned technologies, methods, or processes prove to be ineffective or unreliable, you will lead efforts, using internal and external resources to rapidly implement design or other plan changes that will allow for reliable manufacturing. Once initial processes are defined, you will focus on quality assurance activities that will ensure reliable implementation and use of the product.

Key Responsibilities

• Lead the AP50 Project through all phases of Manufacturing Readiness, including design validation, tooling development, and manufacturing process verification.
• Collaborate with other developers and operations staff to ensure seamless transfer of methods and technologies from concept to manufacturing.
• Develop, implement, and maintain process documentation, including Standard Operating Procedures (SOPs), work instructions, and process flow diagrams.
• Conduct risk assessments, process audits, and ensure compliance with industry standards, safety regulations, and quality requirements.
• Provide oversight of all manufactured components both within AOS and the supply chain, ensuring they meet design specifications and quality standards.
• Operate and train team members on advanced technologies and techniques for manufacturing optical systems.
• Cultivate collaborative relationships with academic and industry partners to drive innovation and stay current with emerging technologies.
• Lead on-the-floor troubleshooting and problem-solving to address any production challenges.
• Innovate and develop new in-house processes, products, and technology, executing development projects to meet project objectives.
• Provide technical leadership and mentorship to junior engineers, fostering a culture of continuous learning and knowledge sharing.
• Monitor and track process performance, using metrics to identify areas for improvement and enhance overall production efficiency.
• Document processes, collaborate with the quality team on QA operations, and ensure compliance with industry standards.
• Offer hands‑on support for assembly processes and ensure successful integration of the system components.
• Communicate across AOS team members, key suppliers and customers.

Requirements & Qualifications

• Advanced degree in Manufacturing, Materials, Physics, Optics, Mechanical Engineering, or a related field, with 10+ years of experience in advanced optical systems manufacturing (or equivalent professional experience).
• Expertise in manufacturing and measuring optical components and systems, with a deep understanding of optics, opto‑mechanical metrology, interferometry, image analysis, and precision manufacturing technologies.
• Strong analytical, problem‑solving, and troubleshooting skills, with the ability to analyze complex technical challenges and develop practical solutions.
• Proven ability to lead cross‑functional teams and collaborate effectively with internal and external stakeholders.
• Proficiency in using software tools for problem analysis and optimization.
• A foundation in mathematics and statistical methods, with the ability to apply these to process improvement and troubleshooting efforts.
• Ability to communicate complex technical information clearly, both verbally and in writing.
• A track record of successful project leadership, with the ability to mentor junior engineers and foster a collaborative, high‑performance team culture.
• A natural curiosity and a passion for personal and professional growth, with a drive to advance capabilities both individually and within the team.
• Experience with advanced metrology and manufacturing processes for optical components, including aspheric and freeform surfaces, is highly desirable.

Additional Skills & Qualifications

• Experience in aerospace, defense, or optics manufacturing.
• Six Sigma, Lean Manufacturing knowledge desired
• Ability to lift moderate weights compatible with assembly and metrology tooling
• Proven ability to manage external suppliers, including overseeing vendor selection and performance.
• Knowledge of thermal and environmental considerations in optical systems for space applications is highly beneficial.

Work Schedule

• Full‑time, permanent position with a minimum 40‑hour workweek on‑site.
• Additional hours may be required based on project demands and team performance.

Environment

AOS has the vibe of an innovative start‑up but with the stability of an established company with a large installed base of international customers consisting of major primes and commercial players in the rapidly growing space and fusion energy sectors. Grow your career with us and create your own aperture to the future.

Location

170 Pondview Dr., Meriden, CT 06450 USA