Sr Process Engineer - Optical Solutions R&D (Sealing)

Molex possesses a rich heritage in the optical industry, delivering high-performance, field-proven optical solutions spanning components, modules, and fully integrated line cards.

We provide cutting-edge wavelength management and amplifier technologies, supported by deep optical, mechanical, electrical, and software integration capabilities.

These strengths enable Molex to serve the evolving needs of high-density, high-bandwidth, and flexible optical networks.

The Senior Process Engineer will develop sealing processes for advanced optoelectronic packages (e.g., CPO, ELSFP).

The position requires close collaboration with R&D and product design teams, manufacturing, suppliers, and customers to ensure product components meet stringent optical, mechanical, and Telcordia reliability requirements.

What You Will Do


* Develop and implement processes to attach various components (e.g., TEC, housing, lid, fiber lens or discrete lenses)


* Own automated process development using die-attach tools (MRSI), including: process set up, alignment and recipes


* Design and implement solder hierarchies (e.g., AuSn, SAC, etc.) to support multiple reflows without reflow or voiding


* Develop hermetic lid-sealing process via electrical or laser welding, or soldering to seal ring


* Develop hermetic fiber-sealing process to housing (e.g., glass frit, Cerrocast) to achieve leak rate ( 5N)


* Partner with product and operation teams to ensure designs are compatible with manufacturable, high-yield assembly flows


* Define process windows, control plans, and critical-to-quality (CTQ) parameters


* Support component supplier selection and evaluation of: housing, lid, seal rings, fiber-feedthrough.

Evaluate process capability and maturity


* Define and oversee component pre-qualification tests to ensure reliable designs (e.g., temperature cycling, damp heat resistance)


* Support failure analysis investigations and corrective actions for product related failures and manufacturing issue (e.g., solder defects (cracks, delamination)


* Drive corrective actions across materials, processes and supplier inputs

Who You Are (Basic Qualifications)


* MS in Material Science, Mechanical Engineering, Physics, Optics, or a closely related field


* At least 10 years of industry R&D experience with solder/epoxy processes used for optoelectronic packages developed and transferred to manufacturing environments


* Hands-on experience with DOE, DFM, statistical tools for efficient optimization (e.g., Minitab or JMP)


* Expertise in solder hierarchy reflow applied to metalized surfaces and bare-glass surfaces


* Experience of process-attach issues (e.g., CTE mismatch, stress, adhesion, thermal limits, etc.)


* Experience with optical components (e.g., gratings, mirrors, lenses), stable attachment methods (e.g., epoxy and solder based)


* Expertise in component qualification methodologies (e.g., GR-468), and product re...