Process Engineer - Laser Welding

Amphenol Communications Solutions; Yocumtown (PA); On-site; USD 90,000 - 140,000; Full time

Job summary

Amphenol Communications Solutions in Valley Green, PA seeks an NPI Engineer specialized in laser welding to lead technology development and production readiness across global sites.

You will define roadmaps, develop robust process windows, perform DOE and QC, and deploy solutions from prototype to MP ramp, with travel up to 30-50%.

Qualifications

• Bachelor's degree in Mechanical, Manufacturing, Optical, Electrical Engineering, Physics, Materials Engineering, or a related technical field.
• 3–5 years of hands-on industrial laser-welding or laser process development experience preferred.
• Strong knowledge of laser-material interaction, weld-joint design, optics, beam delivery, and process monitoring.
• Experience using DOE, SPC, capability analysis, and qualification methods.
• Experience defining and integrating laser-welding equipment into automated systems.

Responsibilities

• Serve as the CBS global technical process owner for laser welding, responsible for technology development and deployment across global sites.
• Define laser-welding technology roadmap and evaluate laser sources, beam-delivery concepts, and automation.
• Collaborate with Product Engineering to assess joint geometry, tolerances, and manufacturability.
• Develop robust process windows using DOE and analysis, including power, speed, focus, and clamp parameters.
• Convert concepts into repeatable production solutions and deploy them through FAT/SAT, site qualification, training, and handoff.
• Lead Phase-gate criteria for equipment, tooling, process window, quality controls, and documentation before each build phase.
• Drive continuous improvement, yield, cycle time, and knowledge capture; support root-cause investigations.

Skills

Laser welding

Process development

DOE

Quality control

Cross-site coaching

Education

Bachelor's degree in Engineering

Job description

Position: NPI Engineer - Laser Welding

Location: Valley Green, Pennsylvania (Global Travel)

Amphenol Communications Solutions (ACS), a division of Amphenol Corporation, is a world leader in interconnect solutions for Communications, Mobile, RF, Optics, and Commercial electronics markets. Amphenol Corporation is one of the world's largest designers and manufacturers of electrical, electronic and fiber optic connectors and interconnect systems, antennas, sensors and sensor-based products and coaxial and high-speed specialty cable. ACS has an expansive global presence in research and development, manufacturing, and sales. We design and manufacture a wide range of innovative connectors as well as cable assemblies for diverse applications including server, storage, data center, mobile, RF, networking, industrial, business equipment, and automotive.

Responsibilities

• Serve as the CBS global technical process owner for laser welding, responsible for technology development, process readiness, qualification, standardization, deployment, and sustained capability across global manufacturing sites.
• Define the laser-welding technology roadmap and evaluate new laser sources, beam-delivery concepts, process monitoring, controls, fixturing, and automation technologies required for future products and manufacturing needs.
• Partner with Product Engineering during concept and design reviews to assess joint geometry, material compatibility, access, tolerance stack-up, clamping, heat input, weldability, inspection method, and overall Design for Manufacturability.
• Develop robust process windows using DOE and engineering analysis, including critical parameters such as power/energy, speed, focus, beam position, shielding, clamping, joint gap, motion, and recipe control.
• Convert proven concepts into repeatable production solutions and deploy them to factories through equipment specification, FAT/SAT, site qualification, training, correlation, production handoff, and post-launch support.
• Process Readiness & NPI Governance - Own laser-welding readiness through prototype, EVT, DVT, PVT, qualification, pilot, and MP ramp. Define phase-gate criteria for equipment, tooling, process window, quality controls, documentation, operator/engineering training, spare parts, and production support before each build phase.
• Process Development & Qualification - Lead welding trials, DOE, destructive and non-destructive evaluation, cross-section/penetration studies where applicable, weld-strength testing, capability analysis, recipe verification, and product-performance validation to establish stable production processes and acceptance criteria.
• Process Controls & Quality Strategy - Define CTQs/CTFs, process monitoring, sampling, control-plan inputs, SPC requirements, golden/reference samples where applicable, recipe limits, alarms, PM/calibration requirements, and reaction plans needed to maintain weld quality and process stability.
• Global Factory Deployment & Site Enablement - Lead technical deployment into CBS factories, including installation readiness, commissioning, FAT/SAT closure, process correlation, qualification, engineering and technician training, troubleshooting, and stabilization through MP ramp.
• Standardization & Technical Governance - Establish approved laser-welding platforms, common equipment specifications, process-development methods, qualification requirements, recipe/version-control rules, change-control expectations, documentation standards, and technical approval criteria for major process changes or deviations.
• Site Team Development & Technical Escalation - Act as the global subject-matter expert for laser welding; coach site engineers, build local capability, support complex root-cause investigations, and provide structured technical escalation when local teams encounter process, equipment, or quality limitations.
• Supplier / Technology Partner Management - Lead technical engagement with laser OEMs, automation integrators, tooling suppliers, and technology partners for feasibility studies, trials, design reviews, FAT/SAT, performance gaps, upgrades, lifecycle support, and future technology development.
• Continuous Improvement & Knowledge Management - Improve yield, weld quality, cycle time, capability, equipment uptime, recipe robustness, maintainability, and cost. Capture lessons learned and convert successful solutions into reusable standards, design rules, troubleshooting guides, and training content.

Qualifications

• Bachelor's degree in Mechanical, Manufacturing, Optical, Electrical Engineering, Physics, Materials Engineering, or a related technical field.
• 3 to 5 years of hands-on industrial laser-welding, laser process development, precision joining, or laser-equipment development experience is strongly preferred.
• Strong knowledge of laser-material interaction, weld-joint design, optics, wavelength/power selection, beam delivery, focus, motion systems, fixturing/clamping, process monitoring, heat-affected-zone considerations, extraction, and industrial laser safety.
• Demonstrated experience developing and qualifying laser-welding processes using DOE, SPC, capability analysis, destructive/non-destructive evaluation, process validation, and structured root-cause analysis.
• Experience defining, specifying, commissioning, and integrating laser-welding equipment into automated manufacturing systems, including FAT/SAT and production handoff.
• Ability to interpret engineering drawings, GD&T/tolerances, material specifications, product requirements, and quality criteria and translate them into practical welding process limits and controls.
• Strong hands-on troubleshooting, technical documentation, supplier-management, training, and cross-site coaching skills; ability to influence global teams without direct authority.
• Experience with high-speed interconnect, cable, connector, electronics, precision assembly, or other high-volume manufacturing environments is preferred.
• Travel - Approximately 30-50% domestic and international travel, with increased travel during process development, factory deployments, qualifications, and major production ramps.

Amphenol Corporation is proud of our reputation as an excellent employer. Our focus is to provide the highest level of support and responsiveness to both our employees and our customers, the world's largest technology companies. Amphenol Corporation offers the opportunity for career growth within a global organization. We believe that Amphenol Corporation is unique in that every employee, regardless of his or her position, has the ability to positively impact the business.

Amphenol is an "Equal Opportunity Employer" - Minority/Female/Disabled/Veteran/Sexual Orientation/Gender Identity/National Origin. For additional company information please visit our website at https://www.amphenol-cs.com/