Senior R&D Process Engineer - Advanced Manufacturing

Keysight Technologies SAles Spain SL.; Santa Rosa, Northern (CA, KY); Hybrid; USD 138,000 - 231,000; Full time

Job summary

Keysight is seeking a highly motivated Senior R&D Engineer to lead development and commercialization of advanced manufacturing processes in Santa Rosa, CA. You will drive process development, DFM, tooling design, and cross-functional collaboration from concept through production.

The role requires deep technical expertise in laser processing, heat-treat forming, additive manufacturing, and advanced packaging, with a strong emphasis on quality, repeatability, and process control.

Qualifications

• MS or PhD in Mechanical Engineering, Materials Science, Manufacturing Engineering, Chemical Engineering, Physics, or related technical discipline.
• 5+ years of experience in process development, manufacturing engineering, or R&D.
• Experience with advanced manufacturing or semiconductor-related processes.
• Strong understanding of Design for Manufacturing (DFM) principles.
• Experience designing fixtures, tooling, and manufacturing processes.
• Excellent problem-solving, statistical analysis, and experimental design skills.
• Strong communication skills with the ability to interact directly with customers and cross-functional teams.

Responsibilities

• Develop, optimize, and qualify advanced manufacturing processes including laser processing, heat-treat forming, PolyIron technology, chemical milling, additive manufacturing, advanced packaging technologies, and float-zone crystal growth.
• Lead process characterization, DOE activities, root-cause analysis, and yield improvement efforts.
• Drive technology transitions from R&D into pilot and production environments.
• Establish process controls, specifications, and documentation to ensure repeatability and quality.
• Partner with product design engineers to ensure manufacturability of new products.
• Provide DFM recommendations during product development and NPI phases.
• Identify process capabilities, limitations, and cost drivers to optimize product designs.
• Design fixtures, tooling, and manufacturing aids to improve process capability and throughput.
• Develop and maintain manufacturing programs and process recipes.
• Utilize CAD tools, preferably Siemens NX, to create tooling and manufacturing designs.
• Conduct process characterization using analytical techniques such as SEM analysis, cross-section analysis, dimensional metrology, surface and material characterization.
• Support materials evaluations and crystal growth studies.
• Analyze experimental data and prepare technical reports and recommendations.
• Serve as a technical interface for customers and internal stakeholders.
• Support customer design reviews, technical discussions, and problem-solving activities.
• Develop technical proposals, process estimates, and manufacturing cost models.
• Provide technical guidance on process capability, risk assessment, and manufacturing readiness.
• Drive productivity, quality, cycle time, and cost-reduction initiatives.
• Identify and implement innovative manufacturing technologies and automation opportunities.
• Support creation of technology roadmaps and strategic capability development plans.

Job description

Keysight is seeking a highly motivated Senior R&D Engineer to lead development and commercialization of advanced manufacturing processes in Santa Rosa, CA. You will drive process development, DFM, tooling design, and cross-functional collaboration from concept through production.

The role requires deep technical expertise in laser processing, heat-treat forming, additive manufacturing, and advanced packaging, with a strong emphasis on quality, repeatability, and process control.