Lead Process Engineer

Job Description

Job Description

Lead Process Engineer

Los Angeles, CA (in-person)

Arcturus is creating a new wire technology stack that uses carbon nanomaterials to overcome the materials limitations of metals where performance breaks down, at real operating temperatures. Our technology is designed to significantly improve the performance of electric motors for drones and robotics, heat sinks, and ultimately the entire energy grid. At its core, Arcturus is developing a new class of carbon nanomaterial-infused metal matrix composites for high-performance conductor applications.

This is a ground-floor opportunity to help build something that has never been done before.

You would join as a founding engineer and become Arcturus’ first processing engineer, with the chance to define the company’s strategy from the beginning. As the founding process engineer, you’ll work directly with the founder/CEO to shape the technical direction of the company, translate scientific insight into real product performance, and help build a category-defining materials platform from scratch.

We are seeking a Lead Processing Engineer who can own the end-to-end process flow that turns early prototypes into reliable, repeatable, and scalable conductor products. This is a hands-on leadership role spanning feedstock preparation, build recipes, carbon infusion or growth steps, post-processing, QA controls, documentation, and pilot readiness.

End-to-end process ownership

• Own Arcturus’ R&D-to-pilot process flow, from feedstock handling and preparation through LPBF/DED processing, carbon infusion or growth steps, post-processing, finishing, inspection, and sample release

• Translate early technical learnings into repeatable process recipes, standard work, process flow diagrams, and controlled operating procedures

• Define critical process parameters and critical quality attributes across each step of the conductor manufacturing flow

• Establish pragmatic process controls that preserve electrical conductivity, thermal performance, mechanical integrity, and nanomaterial stability

• Partner with additive manufacturing and nanomaterials leads to ensure each process step is technically sound, measurable, and scalable

Process development and optimization

• Build and run a disciplined design of experiments (DOE) cadence to expand process windows, improve repeatability, increase yield, and reduce cycle time

• Develop process maps that connect feedstock, atmosphere, laser parameters, thermal history, growth or infusion conditions, and post-processing to final material performance

• Identify bottlenecks, failure modes, and sources of variation, then drive practical solutions that improve consistency and throughput

• Use data analysis, structured root-cause methods, and hands-on experimentation to troubleshoot failed builds, inconsistent samples, or missed performance targets

• Help decide when a process is ready to move from exploratory R&D to controlled development and eventually pilot production

Quality, documentation, and pilot readiness

• Build startup-appropriate quality systems, including control plans, lot tracking, travelers, acceptance criteria, test plans, and traceable build records

• Write and maintain process specifications, work instructions, checklists, and documentation that technicians and engineers can actually use

• Define sample release criteria for internal testing, third-party validation, customer demos, and pilot programs

• Support process qualification plans for conductor materials, printed parts, and wire forms as Arcturus moves toward external validation

• Track process health metrics such as yield, repeatability, build success rate, cycle time, material usage, and throughput

Cross-functional leadership

• Partner closely with nanomaterials, additive manufacturing, characterization, mechanical, and product engineering to tie process variables to conductivity, thermal performance, mechanical properties, and reliability

• Own process-facing vendor and partner relationships, including equipment suppliers, metrology providers, external test labs, and validation partners

• Help translate characterization results into material specs, process windows, acceptance criteria, and clear technical decisions

• Hire and lead process engineers, technicians, and operators as the team scales

• Contribute to invention disclosures, patent strategy, and internal technical documentation with a high bar for rigor and clarity
  

Basic qualifications

• BS, MS, or PhD in materials science, metallurgical engineering, chemical engineering, mechanical engineering, manufacturing engineering, physics, or a related field

• 8+ years of hands-on process engineering, manufacturing engineering, materials processing, or advanced process development experience

• Deep experience developing and scaling complex manufacturing processes in a hardware, materials, or advanced manufacturing environment

• Strong understanding of process-structure-property relationships in metals, metal matrix composites, or other high-performance material systems

• Experience using DOE, statistical analysis, process controls, and structured root-cause methods to improve yield, repeatability, and performance

• Strong scientific and technical writing skills, including clear documentation of process development, test plans, specifications, and invention disclosures
  

Preferred qualifications

• Experience with LPBF, DED, laser processing, welding, CVD/LCVD/LACVD, high-temperature gas processes, or related advanced manufacturing methods

• Experience with aluminum, copper, conductor materials, or metal matrix composites

• Direct experience with carbon nanomaterial-metal composites, covetics, graphene, carbon nanotubes, or carbon-metal interface engineering

• Experience building process controls for new materials, new equipment, or first-of-its-kind manufacturing workflows

• Familiarity with conductor, cable, automotive, aerospace, energy, or utility qualification pathways

• Experience working in a startup or fast-paced R&D-to-manufacturing environment
  

What we offer

• Competitive cash compensation and meaningful equity

• Scientific ownership with direct product impact

• The chance to define the playbook for nanomaterial-enhanced conductors

• Relocation support for candidates moving from outside the Los Angeles area

• Visa sponsorship for highly qualified candidates (H-1B transfers, F-1, or STEM OTP)