Manufacturing Engineer Jobs in Santa Rosa, CA (NOW HIRING)

The TeraWave program is developing next-generation optical telescopes for space-based laser communication terminals (lasercom) operating in medium Earth orbit (MEO). These precision optical systems enable high-throughput data relay at rates exceeding 100 Gbps - forming the backbone of future space communication architectures. Our telescopes must meet fast paced requirements for wavefront error (WFE), line-of-sight (LOS) stability, and pointing accuracy while surviving launch loads and the orbital thermal environment.

We are scaling from prototype to production-rate manufacturing of flight-qualified optical telescope assemblies - and we need a Manufacturing Engineer who can own the tooling, fixtures, and ground support equipment that make that production line possible.

Special Mentions:

• Travel expectations: Up to 20% (supplier sites, test facilities, launch integration)

As the Manufacturing Engineer - Tooling & GSE, you will be the technical owner of all production tooling, alignment fixtures, handling equipment, and ground support equipment used to assemble, integrate, align, test, and transport precision optical telescope assemblies. You will bridge the gap between design engineering and the production floor - translating optical and opto-mechanical designs into robust, repeatable, and technician-executable manufacturing processes.

This is a hands-on, production-focused role. You will design fixtures, prove them out on the floor, iterate based on real build data, and ensure every tool and process meets the precision and cleanliness demands of spaceflight optical hardware.

Tooling & Fixture Design

• Design, develop, and qualify precision production tooling, including alignment nests, bondline gauges, shim kits, potting fixtures, optical handling fixtures, integration jigs, and custom assembly aids for optical telescope assemblies
• Own the full lifecycle of tooling - from concept through design, fabrication, first-article tryout, iteration, qualification, and production release
• Ensure all tooling meets requirements for positional accuracy, repeatability, thermal stability, contamination compatibility, and operator ergonomics
• Apply kinematic and semi-kinematic design principles to ensure deterministic, repeatable positioning of optical elements

Ground Support Equipment (GSE)

• Design and qualify all mechanical GSE for handling, transport, storage, and environmental testing of optical telescope assemblies and subassemblies
• Develop GSE for vibration, shock, and thermal vacuum (TVAC) test campaigns - including test fixtures, adapter plates, thermal straps, and transport containers
• Design handling GSE that protects sensitive optical surfaces, coatings, and precision interfaces during all phases of production and test
• Maintain a GSE inventory, configuration control, and calibration/maintenance schedule for all production tooling and equipment

• Lead Design for Manufacturing (DFM) and Design for Assembly (DFA) reviews with the optical, mechanical, and systems design teams - providing actionable feedback to improve manufacturability, reduce cycle time, and minimize assembly risk
• Author and maintain manufacturing process plans, routers, travelers, and detailed work instructions for all optical telescope assembly and integration operations
• Develop and implement poka-yoke (error-proofing) strategies to minimize operator-dependent variation in precision assembly steps
• Define and optimize assembly sequences to minimize handling of sensitive optical components and reduce contamination risk

• Implement and monitor Statistical Process Control (SPC) for critical manufacturing parameters, tracking process capability indices (Cpk) against defined targets
• Support Measurement System Analysis (MSA) and Gage Repeatability & Reproducibility (GR&R) campaigns to validate measurement systems used in production
• Lead or contribute to Process FMEA activities, identifying and mitigating manufacturing risks before production release
• Support Production Part Approval Process (PPAP) and First Article Inspection (FAI) activities
• Conduct root-cause investigations and corrective actions (RCCA) for tooling-related nonconformances, yield issues, or production escapes
• Ensure all tooling, GSE, and processes comply with AS9100, company quality standards, and applicable NASA/DoD workmanship requirements

• Lead rapid prototyping of tooling and fixtures - leveraging 3D printing, quick-turn machining, and bench-level tryouts to accelerate design iteration
• Create closed-loop feedback between prototype builds, production data, and tooling design - continuously improving cycle time, yield, and repeatability
• Drive Lean manufacturing and continuous improvement initiatives on the production floor

• Create and maintain detailed engineering drawings (per ASME Y14.5 GD&T standards) for all tooling and GSE
• Document procedures, inspection criteria, and acceptance requirements for all tooling and GSE
• Ensure compliance with contamination control and cleanroom protocols (e.g., IEST-STD-CC1246, NASA-STD-6016) applicable to precision optical hardware
• Maintain tooling and GSE configuration under PLM/PDM revision control

• Bachelor's degree (or higher) in Mechanical Engineering, Manufacturing Engineering, Aerospace Engineering, Industrial Engineering, or a closely related field
• 7+ years in a production-focused manufacturing engineering role involving tooling design, fixture development, and/or GSE design for precision hardware systems (aerospace, defense, space, medical devices, or equivalent high-reliability industry)
• Demonstrated hands-on experience designing, fabricating, and qualifying precision fixtures, alignment tooling, handling GSE, and/or inspection gages - not just CAD modeling, but floor-level prove-out and iteration
• Proven ability to lead DFM/DFA reviews with design teams and translate design intent into manufacturable, repeatable production processes
• Strong command of geometric dimensioning and tolerancing per ASME Y14.5; experience performing or leading tolerance stack-up analyses (1D and/or 3D) for precision mechanical assemblies
• Expert proficiency in at least one major CAD platform: PTC Creo (preferred), NX, or SolidWorks - including part/assembly modeling, drawing generation, and basic simulation
• Familiarity with AS9100 / ISO 9001 quality management systems; working knowledge of SPC, GR&R, and process capability concepts
• Hands-on familiarity with common manufacturing processes - machining (CNC mill/lathe), sheet metal, bonding/adhesives, fastening, precision cleaning, and mechanical assembly

• Experience handling, assembling, or integrating sensitive optical components - lenses, mirrors, prisms, optical coatings, fiber-coupled assemblies. Understanding of contamination control, coating damage prevention, and precision optical alignment constraints
• Experience standing up a new production line or transitioning prototype-to-production for space-qualified hardware; familiarity with space qualification processes (protoflight, qualification, acceptance)
• Experience designing fixtures or GSE for vibration, shock, and thermal vacuum (TVAC) test campaigns; understanding of test fixture design constraints (e.g., resonance avoidance, thermal isolation, mass budgets)
• Direct experience leading or contributing to Process FMEA and PPAP in an aerospace or high-reliability production environment
• Hands-on experience implementing SPC control charts (X-bar/R, I-MR) and driving process capability improvements toward Cpk targets
• Experience working in Class 100K or better cleanroom environments; familiarity with IEST-STD-CC1246, NASA-STD-6016, or equivalent contamination control standards
• Experience with product lifecycle management tools (e.g., PTC Windchill, Siemens Teamcenter, or equivalent) for configuration control of tooling and GSE
• Knowledge of vacuum-compatible materials and outgassing requirements (e.g., ASTM E595) for tooling and GSE used in TVAC or flight-adjacent applications
• Lean manufacturing certification (Green Belt or higher) or demonstrated experience applying Lean/Six Sigma tools (DMAIC, 5S, value stream mapping) in a production environment
• Experience with additive manufacturing (FDM, SLA, SLS) for rapid tooling prototyping and bench-level prove-out
• Proficiency in Siemens NX in addition to PTC Creo or SolidWorks