Process Engineer - Hermetic Electronic Packaging at Electronic Products Industries Inc – Newburyport, Massachusetts

SUMMARY: The Process Engineer will support the design, development, and manufacturing of hermetic electronic components produced through glass-to-metal sealing and related precision manufacturing processes.

This role combines component design, materials engineering, and manufacturing process development in a high-mix, low-volume production environment where most products are custom engineered for specific customer applications.

The engineer will design components and assembly fixtures in CAD, develop manufacturing processes involving metals, glass, and ceramic materials, and work directly with production personnel to implement and sustain reliable manufacturing operations. Components produced at EPI ultimately operate in aircraft systems, satellites, space hardware, and high-performance communications equipment, where reliability is critical.

• Design components, assemblies, and manufacturing fixtures and tooling using CAD to support hermetic electronic packaging products.
• Develop and optimize glass-to-metal sealing processes used in hermetic microelectronic packaging.
• Design and develop precision assembly processes for electronic components and subassemblies.
• Establish manufacturing processes involving thermal and mechanical processing, including furnace operations, sealing, brazing, and related processes.
• Evaluate material compatibility and performance for metals, glasses, and ceramics used in hermetic packaging.
• Analyze and control process variables including temperature profiles, thermal expansion mismatch, stress development, and materials compatibility.
• Develop work instructions, process documentation, and operator training materials for manufacturing processes.
• Train assembly technicians and equipment operators on new manufacturing processes and product builds.
• Troubleshoot technical issues in production including seal defects, plating adhesion failures, dimensional stack-up issues, and hermetic leak failures.
• Conduct experiments and process studies to improve yield, process capability, and product reliability.
• Implement process controls, statistical monitoring, and continuous improvement initiatives to maintain product quality.
• Collaborate with cross-functional teams including engineering, quality, production, planning, and sales/customer service to meet customer requirements.
• Support new product introduction (NPI) and transition of prototype designs into repeatable manufacturing processes.

• Strong CAD modeling capability for components, assembly, and tooling design.
• Ability to design manufacturing fixtures, jigs, and tooling to support precision assembly operations.
• Solid understanding of materials behavior under thermal and mechanical stress, particularly interactions between glass, metals, and ceramics.
• Knowledge of coefficient of thermal expansion (CTE) matching, hermetic sealing principles, and materials compatibility.
• Experience developing and optimizing manufacturing processes in production environments.
• Strong analytical and troubleshooting abilities related to manufacturing yield and reliability issues.
• Ability to translate engineering designs into robust manufacturing processes and operator instructions.
• Strong written and verbal communication skills to work effectively with engineers, technicians, and operators.
• Ability to work effectively in a fast-paced, high-mix manufacturing environment.

• Hands-On Engineering Mindset – Comfortable working both in engineering design tools and directly on the manufacturing floor.
• Technical Problem Solving – Ability to diagnose complex manufacturing and materials-related challenges.
• Manufacturing Process Development – Capability to develop new processes and improve existing ones for reliability and efficiency.
• Cross-Functional Collaboration – Effective collaboration with engineering, production, and quality teams.
• Attention to Detail – Focus on precision manufacturing and high-reliability product requirements.
• Continuous Improvement Orientation – Commitment to improving processes, yield, and product performance.
• Adaptability – Ability to work in an environment where products are frequently custom engineered.

• Bachelor’s degree in one of the following disciplines: Mechanical Engineering, Materials Science or Materials Engineering, Manufacturing Engineering, Process Engineering, or equivalent engineering discipline
• 10+ years of engineering or manufacturing experience preferred, particularly in environments involving precision component manufacturing or electronic packaging.
• Experience in one or more of the following areas is highly desirable: glass-to-metal seal technology, hermetic electronic packaging, aerospace or optoelectronic components, precision component assembly, thermal processing or furnace operations, electroplating or surface finishing, ceramic packaging systems
• Candidates with fewer years of experience but strong technical aptitude and hands-on engineering skills may also be considered.
• This role would be a good fit for the engineer who enjoys:
  • Solving materials problems where microns of dimensional change or small thermal expansion mismatches can determine whether a component succeeds or fails.
  • Designing manufacturing processes where temperature profiles, materials compatibility, and mechanical constraints must all work together.
  • Figuring out why something that should work in theory fails during real manufacturing.
  • Working in environments where engineering judgment and hands-on experimentation matter more than following predefined procedures.
  • Seeing components, you helped design and manufacture eventually operate in aircraft, satellites, and other mission-critical systems.

• Familiarity with statistical process control, DOE, Six Sigma, or Lean manufacturing methods is a plus.
• Ability to work effectively in a small to mid-sized engineering organization where engineers play a direct role in both product development and manufacturing.
• Must be highly motivated, detail oriented, and capable of working independently and collaboratively.