R&D Laser Process Engineer

W. L. Gore & Associates, Inc.; Flagstaff (AZ); On-site; USD 100,000 - 130,000; Full time

Job summary

Gore is seeking a Laser Process Engineer for the Rapid Prototype Development group in the Metals R&D team. You will hands‑on develop laser processes for metal implant components, run DOE studies, and create tooling and fixtures using CAD/CAM and 3D printing.

You will also advance laser‑based processes from prototypes to manufacturing validation. The role is based in Flagstaff, AZ, with responsibilities spanning process development, data‑driven optimization, and coordination of activities with

Qualifications

• BS in a technical field (Mechanical, Physics, Materials, CS, etc.)
• 3+ years of industrial manufacturing or R&D process support experience
• 2+ years SolidWorks CAD modeling for rapid fixture development
• Proficiency with CAD/CAM software (SolidWorks, AlphaCAM, Aerotech CADFusion)
• Experience with JMP or Minitab for statistical analysis
• Experience writing and implementing ISO‑compliant quality system reports
• Excellent verbal communication and customer service
• Strong time management and organizational skills
• Hands‑on mechanical aptitude; lift up to 25 lbs and stand for extended periods
• Willing to travel up to 10%

Responsibilities

• Safely operate laser, heat treatment, and electropolishing processes.
• Develop novel laser applications (cutting, ablation, welding) and specify laser sources and delivery systems.
• Design and execute complex DoE to map the process window and optimize parameters.
• Generate custom laser toolpaths using CAD/CAM software and post-processing scripts.
• Design and fabricate fixtures; use 3D printing for prototype parts.
• Verify conformance to specifications; perform measurement system analysis to ensure inspection reliability.
• Generate machine specs, process documents, experimental work plans, and manufacturing instructions.
• Deliver presentations to peers and project customers.
• Build medical device proof-of-concept prototypes and maintain traceability.
• Perform routine calibration, daily checks, and maintenance; coordinate with vendors.
• Maintain a clean lab and manage lab resources and 6S practices.

Job description

About the Role

We are looking for a Laser Process Engineer to join our Rapid Prototype Development group within the Metals R&D team. Servicing a broad range of Gore Medical customer teams, you will help deliver high-precision metal implant and delivery system components using state-of-the-art laser cutting, heat treatment, electropolishing, and automated inspection systems. You will initially engage in hands-on laser process development - ability to run laser processes, cut parts and troubleshoot systems, while also developing and improving new and existing laser-based processes through hands-on experimentation, prototype development, optical system design, automation, and data-driven process optimization. Long-term, you will be expected to engage in other aspects of process development for laser-cut metallic and non-metallic medical device components - from proof-of-concept prototypes to sustained manufacturing validation - planning, and coordinating engineering activities, capability studies, and root cause investigations in support of standard production and new product development.

This role will be located at our facility in Flagstaff, Arizona.

Responsibilities

• Safely and efficiently operate state-of-the-art laser, heat treatment, and electropolishing processes.
• Develop novel laser applications (cutting, ablation, welding) and specify high-performance laser sources and optical delivery systems
• Design and execute complex Design of Experiments (DOE) to map the process window and optimize laser process parameters
• Generate custom laser processing toolpaths using CAD/CAM software and post processing scripts, including use of Aerotech CADFusion software.
• Design and fabricate custom fixtures to position complex prototype parts during laser processing and inspection, including the use of 3D printing technology
• Verify conformance to specifications and perform measurement system analysis (e.g., Gage R&R, bias, linearity) to ensure inspection reliability using appropriate inspection systems (e.g. Visicon, Nikon, Sensofar, tool scope, etc)
• Generate machine specifications, process documentation, experimental work plans, and manufacturing instructions. Deliver presentations on your work to peers and project customers.
• Perform all aspects of building medical device proof-of-concept prototypes, including material preparation, post processing steps (i.e. de-chipping, cleaning, packaging, etc.), and maintaining traceability.
• Perform routine calibration, daily system checks, and preventative maintenance on laser systems. Coordinate with equipment vendors for advanced maintenance needs.
• Maintain a clean and organized lab environment through active support of R&D Lab 6S principles. When needed, manage operations for the Rapid Prototype Development group, including scheduling of Metals R&D lab resources, tracking of appropriate metrics, and managing relationships with project team customers.

Required Qualifications

• Bachelor of Science in an applicable technical field (e.g. Mechanical Engineer, Physics, Material Science, Computer Science, etc.)
• A minimum of 3 years of industrial manufacturing or R&D process support experience
• A minimum of 2 years experience with SolidWorks CAD modeling for rapid fixture development
• Proficiency using CAD/CAM software, such as SolidWorks, AlphaCAM, Aerotech CADFusion, or similar
• Proficiency using statistical analysis software, such as JMP, Minitab, etc
• Proficiency writing and implementing reports within an industry with ISO certified quality system
• Demonstrated history of providing excellent customer service through strong verbal communication and emotional intelligence
• Strong time management and organizational skills
• Hands‑on mechanical aptitude with physical ability to: lift up to 25 lbs, stand for extended periods, and reach into an laser processing enclosure
• Ability to travel up to 10%

Desired Qualifications

• Advanced technical degree (Masters or PhD)
• Six Sigma Black Belt Certification
• Experience leading small technical teams

What We Offer

Our success is based on the capability and creativity of our Associates, and we are proud to offer a comprehensive and competitive total rewards program that supports your everyday and helps you build your tomorrow.

We provide benefits that offer choice and flexibility and promote overall well-being. And in keeping with our belief that every Associate should share in the collective success of the enterprise; we provide a distinctive Associate Stock Ownership Plan in each country as well as potential opportunities for "profit-sharing".

Learn more at gore.com/careers/benefits

Gore is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, gender, national origin, ancestry, age, status as a qualified individual with a disability, genetic information, pregnancy status, medical condition, marital status, sexual orientation, status as a protected veteran, gender identity and expression, and any other characteristic protected by applicable laws and regulations.

Gore is committed to a drug-free workplace. All employment is contingent upon successful completion of drug and background screening. Gore will consider qualified applicants with criminal histories, e.g., arrest and conviction records, in a manner consistent with the requirements of applicable laws.

Gore requires all applicants to be eligible to work within the United States. Gore generally will not sponsor visas unless otherwise noted on the position description.