Heron Power
Creating the foundational technology to meet tomorrow's complex energy demands.
3 days ago
$150,000 - $200,000
Intermediate (4-7 years), Expert & Leadership (13+ years), Experienced (8-12 years)
Full Time
Scotts Valley, California, United States
Onsite
Company Size
11-50 employees Employees
Service Specialisms
Sector Specialisms
Description
line development
process design
surface treatment
joining methods
automation integration
equipment commissioning
As a Sr./Staff Manufacturing Engineer – Advanced Processes, you will develop, test, deploy, and scale high‑volume manufacturing for power‑electronics assemblies. You will lead process and equipment development for advanced automation/robotics, chemical handling of thermal interface materials and gap fillers, plastics/metals assembly, and surface treatments. You will partner with product, mechanical, and electrical design teams early through DFM, closing the feedback loop to ensure robust products and production lines, and work with external suppliers to deliver scalable, repeatable equipment from concept to ramp.
You will lead line development across multiple process and equipment technologies from concept to ramp.
You will develop and scale processes for thermal interface materials, gap fillers, potting, and related dispense, conveyance, and handling systems.
You will create surface‑treatment processes for plastics and metals, including plasma/corona treatment, chemical cleaning, and adhesion preparation.
You will collaborate with equipment suppliers and OEMs from concept through FAT/SAT, commissioning, validation, and handoff for lab, pilot, and mass‑production applications.
You will specify, commission, and optimize production‑scale equipment for high‑speed assembly lines and implement in‑line inspection systems to monitor and control quality.
You will characterize material behavior, define robust process windows via DoE, apply PFMEA, control plans, SPC, and structured problem‑solving to maintain world‑class process capability.
You will support automation integration with robots, conveyors, and inline QA.
- Lead development and ramp‑up of high‑volume manufacturing lines for power‑electronics.
- Design and scale processes for thermal interface materials, gap fillers, and potting.
- Develop surface‑treatment processes for plastics and metals.
- Specify and qualify advanced joining methods (ultrasonic, laser, vibration welding).
- Collaborate with suppliers and OEMs from concept through FAT/SAT and production handoff.
- Commission and optimize high‑speed assembly equipment and in‑line inspection systems.
- Perform material characterization, DoE, PFMEA, SPC, and control‑plan implementation.
- Integrate automation solutions including robots, conveyors, and vision‑based QA.
Requirements
bachelor's
7+ years
minitab
doe
robotics
gd&t
You will specify and qualify advanced joining methods such as ultrasonic welding, laser welding/brazing, and vibration welding.
A bachelor’s degree in Manufacturing, Industrial, Mechanical, Electrical, or Chemical Engineering is required. At least 7 years of experience in industrial automation, chemical handling, electromechanical assembly, or related high‑volume manufacturing processes is needed. You must understand creepage/clearance, enclosure sealing, adhesives, and machine interfaces, and be able to characterize and optimize key variables for chemical handling systems.
Proficiency in statistical analysis, SPC, Cp/Cpk studies, hypothesis testing, and tools such as Minitab/JMP is required, along with demonstrated ability to run DoE and optimize complex processes. Experience implementing PFMEAs, control plans, and process flow diagrams is expected.
Hands‑on experience with automation, robotics, PLCs, and vision systems, familiarity with GD&T, tolerance stack‑ups, precision assembly, and knowledge of root‑cause methods (8D, DMAIC, fishbone) are also required.
If you are passionate about technology and thrive in a fast‑paced environment, we invite you to join us in accelerating electrification at Heron Power.
- Bachelor’s degree in engineering (Manufacturing, Mechanical, Electrical, etc.).
- 7+ years experience in industrial automation, chemical handling, or electromechanical assembly.
- Strong statistical analysis skills (Minitab/JMP) and proven DoE expertise.
- Hands‑on experience with robotics, PLCs, vision systems, and GD&T.
Benefits
We recognize that no single individual knows everything, so we learn together and from each other. We strive to create a collaborative, enriching environment that supports personal, technical, and career growth, driven by first‑principles engineering and challenging problems.
Heron Power offers competitive compensation (salary and equity) and benefits, with a salary range of $150,000–$200,000 per year.
- Competitive salary $150k–$200k plus equity and benefits.
Training + Development
Interview process
Visa Sponsorship
Security clearance
Overview
Energy demand across industries is accelerating at an unprecedented pace, and the need for more deployable, efficient, resilient, and scalable infrastructure has never been more critical. The sustainable energy transition alone demands a 3-5x increase in global electricity generation and consumption. Heron Power is building cutting-edge power electronics for the 21st-century grid. We aim to debottleneck the growth of electricity generation and consumption with scalable, innovative, and less costly hardware solutions, accelerating the electrification of everything.