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Senior Process Development Engineer Jobs in Sunnyvale, CA

Coherent

Senior Assembly Development Engineer

Fremont, CA

$123K - $170K/yr

As the Senior Process Development Engineer, you will lead all aspects of development engineering, work with contract manufacturers, for our high-power CW lasers and their packages. This position ...

Bloom Energy

Senior Process Engineer

Fremont, CA · On-site

$98K - $141K/yr

We are looking for a Senior Process Engineer to join our team in one of today's most exciting ... Work in cross-functional teams with Quality, Product Development, and Manufacturing team to develop ...

Bloom Energy

Senior Process Engineer

Fremont, CA · On-site

$98K - $141K/yr

We are looking for a Senior Process Engineer to join our team in one of today's most exciting ... Work in cross-functional teams with Quality, Product Development, and Manufacturing team to develop ...

Cellares

Senior Process Engineer

South San Francisco, CA · On-site

$90 - $210/hr

This position is responsible for supporting the activities involved in the development, process ... Work as the Senior MSAT Process Engineer on client projects * Responsible for technology transfer ...

Blue Current

Sr. Process Engineer

Hayward, CA · On-site

$119K - $154K/yr

The Senior Process Engineer will work cross-functionally to translate evolving process requirements ... Act as the primary engineering owner for assigned battery R&D equipment (e.g., gloveboxes, slurry ...

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All JobsProcess Development Engineer JobsSenior Process Development Engineer JobsSenior Process Development Engineer Jobs in Sunnyvale, CA

Senior Process Development Engineer information

See Sunnyvale, CA salary details

$88K

$142.1K

$200.1K

How much do senior process development engineer jobs pay per year?

As of Sep 3, 2026, the average yearly pay for senior process development engineer in Sunnyvale, CA is $142,148.00, according to ZipRecruiter salary data. Most workers in this role earn between $122,100.00 and $157,900.00 per year, depending on experience, location, and employer.

What does a senior process development engineer do?

A Senior Process Development Engineer is responsible for designing, developing, and optimizing manufacturing processes to improve efficiency, quality, and cost-effectiveness. They often lead teams in scaling up processes from the laboratory to full production, troubleshoot technical issues, and implement new technologies or methods. Additionally, they collaborate with cross-functional teams, including R&D, quality assurance, and production, to ensure processes meet regulatory and safety standards. Their expertise helps companies maintain competitive advantages and meet production goals.

What are the key skills and qualifications needed to thrive as a senior process development engineer?

To thrive as a Senior Process Development Engineer, you need a strong background in chemical or mechanical engineering, process optimization, and project management, typically supported by a relevant engineering degree. Familiarity with CAD software, process simulation tools (such as Aspen Plus or MATLAB), and Six Sigma or Lean Manufacturing certifications is often required. Excellent problem-solving, leadership, and communication skills help you coordinate cross-functional teams and drive continuous improvement. These skills are crucial for developing efficient, scalable processes that meet quality standards and business goals.

What are some common challenges a senior process development engineer may face when scaling up a new process from the lab to full production?

Senior Process Development Engineers often encounter challenges such as maintaining product quality and consistency when transitioning from small-scale laboratory experiments to large-scale manufacturing. This process typically involves troubleshooting equipment limitations, optimizing process parameters, and ensuring compliance with safety and regulatory standards. Effective collaboration with cross-functional teams, such as R&D, manufacturing, and quality assurance, is crucial to address these challenges and achieve a smooth scale-up. Adaptability and problem-solving skills are essential to navigate unexpected issues that may arise during this transition.

What is the difference between Senior Process Development Engineer vs Process Engineer?

AspectSenior Process Development EngineerProcess Engineer
CredentialsBachelor's or Master's in Chemical, Mechanical, or Industrial Engineering; experience in process developmentBachelor's degree in Engineering or related field; entry to mid-level experience
Work EnvironmentResearch and development labs, manufacturing facilities, cross-functional teamsManufacturing plants, production lines, process optimization teams
Industry UsagePharmaceuticals, chemicals, biotech, manufacturingManufacturing, chemical processing, consumer goods

The main difference is that Senior Process Development Engineers focus on developing and optimizing new processes, often in R&D settings, while Process Engineers typically oversee existing manufacturing processes to improve efficiency and quality. Senior roles involve more strategic planning and innovation, whereas Process Engineers focus on day-to-day process operations.

What are popular job titles related to Senior Process Development Engineer jobs in Sunnyvale, CA?

For Senior Process Development Engineer jobs in Sunnyvale, CA, the most frequently searched job titles are:

What job categories do people searching Senior Process Development Engineer jobs in Sunnyvale, CA look for?

The top searched job categories for Senior Process Development Engineer jobs in Sunnyvale, CA are:

What cities near Sunnyvale, CA are hiring for Senior Process Development Engineer jobs?

Cities near Sunnyvale, CA with the most Senior Process Development Engineer job openings:

Senior Process Development Engineer jobs near you
Infographic showing various Senior Process Development Engineer job openings in Sunnyvale, CA as of August 2026, with employment types broken down into 1% As Needed, 83% Full Time, 13% Part Time, and 3% Contract. Highlights an 87% Physical, 3% Hybrid, and 10% Remote job distribution, with an average salary of $142,148 per year, or $68.3 per hour.

Senior Process Engineer

FOXSEMICON TECHNOLOGY LLC

Union City, CA • On-site

$100K - $150K/yr

Full-time

Medical, Dental, Vision, Life, Retirement, PTO

Re-posted 15 days ago

Job description

Benefits:
  • 401(k) matching
  • Dental insurance
  • Health insurance
  • Opportunity for advancement
  • Paid time off
  • Vision insurance

Position: Senior Process Engineer

Hours: 40 hours per week

Position Summary
We are seeking a highly motivated Process Engineer to develop, optimize, and maintain manufacturing processes for semiconductor equipment components, with a focus on precision machining and surface treatment. This role requires knowledge in metal processing, hands-on troubleshooting ability, and cross-functional collaboration to support quality, cost, and delivery targets.
Responsibilities
  • Develop and optimize processes for precision machining (e.g., CNC milling, turning, tapping) of complex metal parts such as chambers, showerheads, and manifolds.
  • Evaluate machining risks for critical components and define appropriate tolerances, and process flow.
  • Identify and manage surface treatment requirements, including chemical cleaning, anodizing, electropolishing, passivation, and plating.
  • Define and validate process controls to ensure dimensional accuracy, surface quality (Ra/Rz), and contamination control standards (e.g., particle level, ionic contamination).
  • Lead root cause analysis for process failures and implement corrective actions using engineering tools (e.g., 5-Why, Fishbone, DOE).
  • Collaborate with quality, planning, and supplier teams to manage internal and outsourced processes.
  • Support new product introduction (NPI) by coordinating process development, tooling, fixture design, and pilot build.
  • Maintain clear and up-to-date documentation such as SOPs, process specifications, and control plans..
  • Additional duties as defined by manager
Qualifications
  • Bachelor of Science degree or equivalent of work experience
  • 5+ years of hands-on experience in precision machining and surface treatment processes for metal components. Experience evaluating and troubleshooting manufacturing processes and machinery
  • Experience using CAD, CAM, data analysis programs, and related software
  • Excellent communication skills, both verbal and written
  • Strong organization and management skills
  • Proficiency in Microsoft Office
  • High level of technical expertise
  • Strong analytical thinker
Benefits
  • 100% company-paid health insurance (Medical/Dental/Vision) for employees
  • Life and AD&D insurance
  • Paid time off and 10-holiday pay
  • Flexible Spending Account (FSA)
  • 401k with company matching up to 4%