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Commonwealth Fusion Systems is seeking a Fiber Optics Manufacturing Engineer to develop, scale, and continuously improve manufacturing processes for fiber optic cables and assemblies critical to fusion energy systems. This role bridges R&D and production, working across Devens and Somerville locations to transition fiber optic products from prototype into reliable, repeatable manufacturing.
You will partner with Fiber Optic Specialists, production technicians, design engineering, quality, and test teams to develop standardized processes for fiber handling, routing, splicing, wrapping, jacketing, bonding, termination, and cable assembly. Key responsibilities include developing manufacturing processes and controls that prevent fiber damage, optimizing tooling and workstations, and applying Design for Manufacturing (DFM) and Design for Assembly (DFA) principles with design engineering.
You will establish manufacturing process parameters, acceptance criteria, inspection methods, and process controls for critical fiber optic processes. This includes creating and maintaining comprehensive manufacturing documentation (work instructions, process flow diagrams, pFMEAs, SOPs, process control plans) and partnering with Quality and Test Engineering to develop effective inspection and test methods.
Using manufacturing and optical performance data, you will identify sources of variation, establish process capability, and improve first-pass yield, scrap, rework, cycle time, and throughput. You will troubleshoot manufacturing and quality issues using structured root-cause analysis, experiments, and data analysis. You will lead continuous improvement and RCCA projects, provide hands-on technical support and training to production personnel, and support manufacturing capacity planning and process scaling.
Required: Bachelor's degree in Mechanical, Manufacturing, Industrial, or Optical Engineering (or equivalent); 5+ years of manufacturing engineering experience with fiber optic, optical, cable assembly, or precision assembly processes; direct hands-on experience with fiber optic manufacturing, cable assembly, optical fiber handling, splicing, or testing; strong understanding of process development, control, troubleshooting, and continuous improvement; experience with Lean Manufacturing, Six Sigma, RCCA, DOE, SPC, or structured problem-solving; strong analytical and communication skills; ability to work in fast-paced environments managing multiple priorities.
Bonus: Experience with fiber optic cable manufacturing, fiber routing, splicing, termination, wrapping, jacketing, or optical assemblies; experience with optical performance measurements (attenuation, insertion loss, continuity, spectral analysis); familiarity with OTDR, OSA, OBR, or optical test equipment.
