Senior R&D Process Engineer

is at the forefront of technology innovation, delivering breakthroughs and trusted insights in electronic design, simulation, prototyping, test, manufacturing, and optimization. Our ~16,800 employees create world-class solutions in communications, 5G, automotive, energy, quantum, aerospace, defense, and semiconductor markets for customers in over 100 countries. Learn more 

Our culture embraces a bold vision of where technology can take us and a passion for tackling challenging problems with industry-first solutions. We believe that when people feel a sense of belonging, they can be more creative, innovative, and thrive at all points in their careers.

We are seeking a highly motivated Senior R&D Engineer to lead the development and commercialization of advanced manufacturing processes and technologies. This role will be responsible for process development, design-for-manufacturing (DFM), fixture and tooling design, customer technical engagement, and continuous improvement of specialized fabrication technologies including laser processing, heat-treat forming, Poly Iron, chemical milling, additive manufacturing, crystal growth, and advanced packaging solutions.

The ideal candidate combines strong technical depth with hands-on problem solving and cross-functional collaboration to develop innovative manufacturing solutions from concept through production.

Process & Technology Development

• Develop, optimize, and qualify advanced manufacturing processes including:
• Laser processing
• Heat-treat forming
• PolyIron technology
• Chemical milling
• Additive manufacturing
• Advanced packaging technologies
• Float Zone crystal growth
• Lead process characterization, DOE activities, root cause analysis, and yield improvement efforts.
• Drive technology transitions from R&D into pilot and production environments.
• Establish process controls, specifications, and documentation to ensure repeatability and quality.

Design for Manufacturing (DFM)

• Partner with product design engineers to ensure manufacturability of new products.
• Provide DFM recommendations during product development and NPI phases.
• Identify process capabilities, limitations, and cost drivers to optimize product designs.

Tooling, Fixture, and Programming Development

• Design fixtures, tooling, and manufacturing aids to improve process capability and throughput.
• Develop and maintain manufacturing programs and process recipes.
• Utilize CAD tools, preferably Siemens NX, to create tooling and manufacturing designs.

Materials & Process Characterization

• Conduct process characterization using analytical techniques such as:
• SEM analysis
• Cross-section analysis
• Dimensional metrology
• Surface and material characterization
• Support materials evaluations and crystal growth studies.
• Analyze experimental data and prepare technical reports and recommendations.

Customer & Business Support

• Serve as a technical interface for customers and internal stakeholders.
• Support customer design reviews, technical discussions, and problem-solving activities.
• Develop technical proposals, process estimates, and manufacturing cost models.
• Provide technical guidance on process capability, risk assessment, and manufacturing readiness.

Continuous Improvement

• Drive productivity, quality, cycle time, and cost reduction initiatives.
• Identify and implement innovative manufacturing technologies and automation opportunities.
• Support creation of technology roadmaps and strategic capability development plans.

• MS or PhD in Mechanical Engineering, Materials Science, Manufacturing Engineering, Chemical Engineering, Physics, or related technical discipline.
• 5+ years of experience in process development, manufacturing engineering, or R&D engineering.
• Experience with advanced manufacturing or semiconductor-related processes.
• Strong understanding of Design for Manufacturing (DFM) principles.
• Experience designing fixtures, tooling, and manufacturing processes.
• Excellent problem-solving, statistical analysis, and experimental design skills.
• Strong communication skills with the ability to interact directly with customers and cross-functional teams.

Santa Rosa, CA Pay Range: MIN $138,000.00 - MAX $231,000.00

This position requires access to certain goods, software, technology, or technical data subject to U.S. export control laws and regulations. Under these laws and regulations, U.S. persons (which includes U.S. citizens, U.S. nationals, lawful permanent residents, refugees, and asylees) working for Keysight can access export-controlled items without authorization from the U.S. government. For any individual who is not a U.S. person, Keysight may need authorization from the U.S. Department of State, U.S. Department of Commerce, or other appropriate federal agency before the individual can access export-controlled items. Employment in this position for non-U.S. persons is contingent on Keysight’s ability to obtain any required government authorizations .

***Keysight is an Equal Opportunity Employer.***