Job Overview

The Senior Manufacturing Process & Development Engineer will serve as the technical lead for establishing, maturing, and scaling DDN’s new in-house laser machining capability within the Advanced Manufacturing Process (AMP) organization. This role will drive advanced process development for high-precision laser machining of metals, polymers, ceramics, composites and thin films with an emphasis on micro-features, tight tolerances, and rapid prototyping solutions.

Key Responsibilities

Laser Machining Capability Development

• Lead all technical activities related to standing up and maturing TE’s in-house laser machining capability.
• Develop, validate, and optimize processes for cutting, drilling, ablation, trimming, and surface texturing of advanced materials with micro-scale features.
• Own the laser system parameters, recipes, alignment methods, fixturing concepts, and metrology strategy.
• Establish process windows, capability baselines (Cp/Cpk), and best-practice work instructions for repeatable, reliable machining performance.
• Strong understanding of laser physics and optics (beam alignment, focusing, pulse/waveform control, material interaction, etc.).
• Program and set up laser systems; adjust laser parameters (power, pulse, beam alignment/spot size, focus, wavelength as relevant) for different materials and process goals.

Process Engineering

• Partner with AMP subject-matter experts to design, execute, and analyze DOE studies related to laser processing of metals, polymers, laminates, and specialty materials.
• Provide hands-on support in running trials, characterizing results, and translating findings into actionable recommendations.
• Develop structured documentation for all experimental runs including parameter sets, material behavior observations, tool wear, debris management, and post-process quality.
• Proficiency in laser system programming and setup; familiarity with CAD/CAM or other tooling software

Collaboration & Cross-Functional Leadership

• Work closely with the laser lab technician to ensure daily alignment, workload balancing, and equipment uptime.
• Partner with Advanced Development Team (ADT), Advanced Solutions Team (AST), and Product Engineering on customer-driven R&D projects and long-range capability roadmaps.
• Provide technical guidance and training to peers and technicians in laser machining fundamentals, equipment operation, and safe practices.
• Collaborate with cross-functional teams (mechanical, electrical, metrology/quality, design, R&D) to integrate laser processes into the broader manufacturing workflow — including tooling, part design, automation, and post-processing steps.

Innovation & Continuous Improvement

• Apply deep knowledge of laser technologies (IR, femtosecond) and micromachining processes in the development of advanced manufacturing systems for precision applications.
• Acts as a technical liaison between product development, process engineering, and advanced manufacturing to ensure seamless integration of automation and laser technologies into production systems.
• Provide training and mentorship to other professional employees.
• Work independently with wide latitude to define project objectives and technical approaches, making key contributions to business unit strategies and goals.

What your background should look like

• Minimum 5 years of relevant industry experience required.
• Bachelor’s Degree (Mechanical Engineering, Mechanical Engineering Technology, Materials Science, Optics/Photonics, Physics or related discipline) preferred; equivalent experience considered (15+ years in relevant roles)
• Hands-on experience with a variety of machining methods preferred, including CNC milling, wire EDM, and manual milling operations preferred.
• Familiarity with manufacturing environments involving Stamping, Plating, Assembly and Molding (SPAM) technologies for precision components is a plus.
• Demonstrated ability to lead cross-functional projects, influence without authority, and deliver measurable outcomes in a manufacturing environment.
• Proficiency in CAD modeling software, including Creo, SpaceClaim, SolidWorks, and other general 3D design tools.
• Willingness to travel up to 25% average.

Competencies