Process Engineer

Process Engineer – Technical Development and Automation / Direct Hire, FTE / 100% onsite in San Carlos, CA / $150-170K annually

Summary:

As a Process Engineer on our Technology Development team, you’ll be at the forefront of building one-of-a-kind manufacturing solutions that don’t just improve processes-they redefine them. Your role will be to design, automate, and implement groundbreaking systems that expand Client’s technical capabilities, accelerate New Product Introduction (NPI), and establish the foundation for scalable, high-performance, automated manufacturing. This is more than engineering-it’s creating the blueprint for the future of power and data transmission. 

Duties and Responsibilities:

• Lead interdisciplinary technology development projects from the ideation phase through full implementation, with a focus on automating manual processes, improving system efficiency, and developing the next generation of processes and equipment for flex manufacturing. 
• Design, implement, and optimize automation solutions, including advanced roll-to-roll systems and precision material handling, that push the limits of cycle time, minimize variability, and improve process reliability. 
• Innovate novel, robust processes for manufacturing flexible circuits that are one-of-a-kind in the industry. 
• Work hands-on with high-volume manufacturing and R&D equipment; Qualify next-generation tools and processes on the manufacturing line. 
• Develop and integrate monitoring, data acquisition, and control systems to provide real-time visibility into process health and performance. 
• Identify opportunities for breakthrough automation, digitalization, and lean improvements that redefine what’s possible in manufacturing.

Required Skills: 

• Bachelor's degree or higher in Materials Science, Physics, Chemical Engineering, Mechanical Engineering, Electrical Engineering, or related technical field. 
• 7+ years of hands-on experience working in process engineering, automation, or manufacturing system development (preferably in NPI or high-mix/mid-volume environments).

• Prior experience with advanced materials and high-volume manufacturing methods (e.g., vacuum lamination, thermally-activated adhesives, roll-to-roll processing, material patterning, laser welding). 
• Prior manufacturing start-up experience. 
• Prior experience developing innovative processes able to scale from NPI to mass production. 
• Solid background in statistical methods, data visualization, systematic experiment design, and related software (e.g., JMP, Minitab, etc.). 
• Ability to synthesize and interpret complex data sets to understand physical phenomena and support data-driven decisions. 
• Ability to safely and confidently operate and troubleshoot custom manufacturing and metrology equipment. 
• Independent problem solver with a desire to learn new skills and new technology.
• Strong organization skills and a detail-oriented mindset. 
• Able to adapt to changing requirements in a fast-paced start-up setting. 
• Excellent communicator and collaborator with a passion for tackling challenges as part of a high-performance team.