Lead Optical Manufacturing Engineer - Space Technologies

AeroVironment • Albuquerque, NM

2d • Onsite

About The Position

The Manufacturing Engineering Team within our Space Technologies area is responsible for developing and scaling assembly, integration, and test operations for next-generation space systems, including optical payloads, laser communication terminals, and space-qualified hardware for satellite and orbital applications. As a critical member of the team, the Optical Manufacturing Engineer will serve as the technical leader translating optical system designs (e.g., for laser comms, imaging, or stabilization payloads) from development into a sustainable, high-yield production environment. You will collaborate closely with design engineers, test engineers, systems engineers, and cross-functional teams to establish optical manufacturing processes and work instructions --from component assembly through final integration and qualification for space environments. This role is ideal for hands-on engineers who thrive on building and testing complex, high-precision optical products in cleanroom settings and take a methodical, innovative approach to pioneering and scaling production for defense and space missions. This is a full-time, in-office position based in our Albuquerque, NM facility.

Requirements

• Bachelor's degree in Optical Engineering, Manufacturing Engineering, Mechanical Engineering with a focus in Optics (Optomechanical), Aerospace Engineering, Electrical Engineering, or a related technical field
• 6 years total relevant experience, of which 3 years directly in the assembly, integration, alignment, and test of complex optical instruments, telescopes, laser systems, or space-based payloads
• Hands-on experience with complex optomechanical assembly, precision alignment, integration, and bonding in cleanroom environments (ISO Class 5 or better)
• Experience leveraging technical software for design, analysis, and test (e.g., Zemax, MATLAB, Python, LabView and/or C/C++)
• Expertise in reading technical drawings and using SolidWorks or equivalent CAD software to develop tooling and fixtures
• Experience defining and implementing manufacturing processes in a production environment, including New Product Introduction (NPI) for high-reliability systems
• Ability to obtain and maintain a US DoD security clearance

Nice To Haves

• Experience with space-qualified optical systems, laser communications, directed energy optics, fiber optics, and/or hyperspectral/multispectral imaging payloads
• Experience implementing successful continuous improvement methodologies (e.g., Lean, Six Sigma) in high-reliability manufacturing
• Familiarity with Manufacturing Execution System (MES) and Product Lifecycle Management (PLM) software
• Experience across the space flight program lifecycle (design through on-orbit operations and qualification)
• Knowledge of MIL-STD, NASA, or DoD standards for space hardware
• Additional education or certifications in relevant engineering or scientific fields
• Solid interpersonal skills and a collaborative, hands-on attitude for working effectively with cross-functional, multi-disciplinary teams
• Excellent attention to detail and technical writing skills for creating detailed procedures, test plans, and data summaries

Responsibilities

• Support the Assembly, Integration, and Test (AI&T) of optical payloads and space-qualified systems, including laser communication terminals and imaging/stabilization hardware
• Develop/document optical assembly procedures and work instructions, including precise metrology, alignment (warm/cold), bonding, and performance testing in simulated space conditions
• Design, develop, and implement mechanical/electrical tooling, fixtures, and Ground Support Equipment (GSE) for optical assembly and test in cleanroom environments
• Perform analysis of measured data for alignment, calibration, characterization, and environmental qualification; monitor production metrics and yield
• Drive timely resolution of non-conformances (NCRs), conduct root cause analysis, implement corrective actions, and lead continuous improvement initiatives
• Provide critical Design for Manufacturability (DFM) and Design for Assembly (DFA) feedback to optical, mechanical, and systems design teams
• Provide technical oversight for external vendors and suppliers involved in optical component fabrication, coatings, and assembly
• Participate in training production technicians to transition manufacturing lines from R&D/prototyping to scaled production
• Recommend facilities, capital equipment, and process improvements to scale space-qualified manufacturing operations

Benefits

• AV offers an excellent benefits package including medical, dental vision, 401K with company matching, a 9/80 work schedule and a paid holiday shutdown.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level