R&D Laser Process Engineer
About the Role
We are looking for a Laser Process Engineer to join our Rapid Prototype Development group within the Metals R&D team. Servicing a broad range of Gore Medical customer teams, you will help deliver high-precision metal implant and delivery system components using state-of-the-art laser cutting, heat treatment, electropolishing, and automated inspection systems. You will initially engage in hands-on laser process development – ability to run laser processes, cut parts and troubleshoot systems, while also developing and improving new and existing laser-based processes through hands-on experimentation, prototype development, optical system design, automation, and data-driven process optimization. Long-term, you will be expected to engage in other aspects of process development for laser-cut metallic and non-metallic medical device components – from proof-of-concept prototypes to sustained manufacturing validation - planning, and coordinating engineering activities, capability studies, and root cause investigations in support of standard production and new product development.
This role will be located at our facility in Flagstaff, Arizona.
Responsibilities
- Safely and efficiently operate state-of-the-art laser, heat treatment, and electropolishing processes.
- Develop novel laser applications (cutting, ablation, welding) and specify high-performance laser sources and optical delivery systems
- Design and execute complex Design of Experiments (DOE) to map the process window and optimize laser process parameters
- Generate custom laser processing toolpaths using CAD/CAM software and post processing scripts, including use of Aerotech CADFusion software.
- Design and fabricate custom fixtures to position complex prototype parts during laser processing and inspection, including the use of 3D printing technology
- Verify conformance to specifications and perform measurement system analysis (e.g., Gage R&R, bias, linearity) to ensure inspection reliability using appropriate inspection systems (e.g. Visicon, Nikon, Sensofar, tool scope, etc)
- Generate machine specifications, process documentation, experimental work plans, and manufacturing instructions. Deliver presentations on your work to peers and project customers.
- Perform all aspects of building medical device proof-of-concept prototypes, including material preparation, post processing steps (i.e. de-chipping, cleaning, packaging, etc.), and maintaining traceability.
- Perform routine calibration, daily system checks, and preventative maintenance on laser systems. Coordinate with equipment vendors for advanced maintenance needs.
- Maintain a clean and organized lab environment through active support of R&D Lab 6S principles. When needed, manage operations for the Rapid Prototype Development group, including scheduling of Metals R&D lab resources, tracking of appropriate metrics, and managing relationships with project team customers.
Required Qualifications
- Bachelor of Science in an applicable technical field (e.g. Mechanical Engineer, Physics, Material Science, Computer Science, etc.)
- A minimum of 3 years of industrial manufacturing or R&D process support experience
- A minimum of 2 years experience with SolidWorks CAD modeling for rapid fixture development
- Proficiency using CAD/CAM software, such as SolidWorks, AlphaCAM, Aerotech CADFusion, or similar
- Proficiency using statistical analysis software, such as JMP, Minitab, etc
- Proficiency writing and implementing reports within an industry with ISO certified quality system
- Demonstrated history of providing excellent customer service through strong verbal communication and emotional intelligence
- Strong time management and organizational skills
- Hands-on mechanical aptitude with physical ability to: lift up to 25 lbs, stand for extended periods, and reach into an laser processing enclosure
- Ability to travel up to 10%
Desired Qualifications
- Advanced technical degree (Masters or PhD)
- Six Sigma Black Belt Certification
- Experience leading small technical teams