R&D Laser Process Engineer

W. L. Gore & Associates; Flagstaff (AZ); On-site; USD 90,000 - 130,000; Full time

Job summary

Gore is seeking a Laser Process Engineer for their Rapid Prototype Development group in Flagstaff, AZ. You will hands-on develop laser processes for high-precision metal implant components, while advancing automation, DOE studies, and data-driven optimization.

You will also coordinate experiments, generate toolpaths, fabricate fixtures, and contribute to manufacturing validation and project support within a SOI-driven ISO environment.

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%

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.

Skills

Communication

Time management

Organizational skills

Problem solving

Teamwork

Education

Bachelor of Science in Mechanical Engineering

Bachelor of Science in Physics

Bachelor of Science in Material Science

Bachelor of Science in Computer Science

Tools

SolidWorks

AlphaCAM

Aerotech CADFusion

CAD/CAM software

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.

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.