Senior Opto-Mechanical Engineer, Large Optics Structures

Responsibilities • Develop mounting and support methodologies for large (meter-class), segmented, and lightweight mirrors used in deep-UV, high-energy laser beam transport, including kinematic definition, axial and lateral support schemes, and multi-degree-of-freedom adjustment.

• Architect and design the trusses, weldments, optical benches, and precision adjustment mechanisms that hold those mirrors, optimizing stiffness-to-mass, thermal stability, and resistance to facility-borne vibration.

• Perform structural-thermal-optical performance (STOP) analysis: static, modal, random-vibration, and thermal FEA mapped to optical surface deformation and pointing error, and correlate the models to measured data.

• Define vibration isolation and damping strategies, quantify resonant modes and harmonics against PSD-defined base and impulse sources, and lead modal testing with accelerometers to validate designs.

• Select and specify materials for athermal, dimensionally stable structures (low-CTE metals and ceramics, composites) and define bond-pad and stress-limited mounting approaches for coated DUV substrates.

• Design and validate large-optic handling, lifting, installation, and removal fixtures and procedures with contamination control and personnel safety as first-order requirements.

• Support metrology of mounted optics (interferometry, surface figure, alignment references) and use the results to accept or iterate mount and structure designs.

• Create and maintain interface control documents between optical mounts, supporting structures, facility interfaces, and adjacent subsystems; integrate designs into the large-scale NX assembly of the facility.

• Produce detailed models, GD&T drawings per ASME Y14.5, and technical data packages; release and control drawings through engineering change.

• Specify materials and finishes, manage technical data transfer to machining and fabrication suppliers, and inspect and qualify hardware on receipt.

• Develop and execute assembly, alignment, and test plans in collaboration with manufacturing engineers; assemble prototype hardware and support integration and troubleshooting in the cleanroom and lab.

• Present work at design reviews to optical, controls, manufacturing and science stakeholders; document analyses, decisions, and lessons learned.

• Mentor other mechanical engineers on precision design, analysis, and opto-mechanical integration.

Qualifications • Education : B.S. in Mechanical Engineering, Optical Engineering, or a related field.

• Experience : 10+ years of opto-mechanical engineering experience, including full lifecycle ownership (concept, analysis, procurement, assembly, test) of precision optical hardware.

• Demonstrated experience designing mounts and support structures for large optics (meter-class apertures), including truss or weldment structures for support and adjustment.

• Experience designing and characterizing optical mounts in the presence of PSD-defined base and external vibration, including quantifying resonant modes and harmonics and correlating FEA to modal test data.

• Working knowledge of athermal design: CTE matching, thermal gradient and soak effects on figure and alignment, and low-expansion material selection.

• Understanding of gravity-induced sag and print-through and the mount strategies used to control them.

• Strong FEA skills (static, modal, random vibration, thermal) in standard tools such as Ansys, Abaqus, or Nastran, and the ability to fit and decompose deformed optical surfaces (e.g., Zernike or rigid-body fits) into figure and pointing errors.

• Experience implementing alignment references and integrating optical subsystems containing flat, powered, and off-axis mirrors.

• Ability to build tolerance stack-ups for optical sensitivity analysis and a clear understanding of how mechanical tolerances translate into optical tolerances.

• Fluency in 3D CAD (NX preferred; SolidWorks or Creo acceptable) and in creating drawings using GD&T per ASME Y14.5.

• Practical knowledge of machining, welding, and fabrication processes and design for manufacturability for large precision structures.

• Experience creating and maintaining interface control documents.

• Comfort working in cleanroom, high-vacuum, and high-voltage environments.

• Strong written and verbal communication and a track record of clear technical documentation.

Desired • M.S. or Ph.D. in Mechanical Engineering, Optical Engineering, or a related field.

• Experience with segmented mirror arrays or large-format mirrors greater than 1 m, including multi-DOF mounts and array-level alignment.

• Design, fabrication, or optimization of lightweight mirror substrates.

• Active mount pointing and alignment recovery, including slow and fast steering mirrors.

• Experience with high-energy laser systems, particularly in the deep UV, and with laser-induced damage considerations for coated optics.

• Hands-on experience with optical fabrication and assembly techniques, including adhesive bonding of optics.

• Experience with vibration isolation systems and facility or slab dynamic characterization.

• Background in large telescope, lithography, or high-energy laser facility opto-mechanics.