Principal Optical Assembly Engineer

About the Role 

Astera Labs is seeking a Principal Optical Assembly Engineer to drive development of optical assembly processes that support next-generation photonics products for scale up and scale out AI infrastructure applications. This is a high-impact individual contributor role with technical leadership responsibilities, focused on developing robust assembly processes, expanding lab capability, and improving the yield, quality, and reliability of optical assemblies for NPO and CPO products. 

Responsibilities 

• Drive development and optimization of optical assembly processes, including active and passive fiber alignment, fiber attach, and epoxy cure. 

• Define and document process flows, work instructions, and quality control plans for optical assembly. 

• Support the build-out and scaling of the optical assembly laboratory, including equipment layout, tool qualification, and safety protocols. 

• Partner with equipment suppliers on the development and qualification of high volume capable active alignment systems, dispensing tools, and curing tools.  

• Qualify optical adhesives and encapsulants with material vendors for optical performance, thermal and mechanical requirements, process scalability, and reliability. 

• Develop yield improvement plans and implement statistical process control (SPC) methods for optical assembly. 

Basic Qualifications 

• B.S., M.S., or Ph.D. in Electrical Engineering, Mechanical Engineering, Materials Science, Optical Engineering, or a related field. 

• 8+ years of experience in optical assembly, photonics packaging, or a related process development role. 

• Hands-on experience developing precision assembly processes for photonic or optoelectronic products. 

• Experience leading optical assembly platforms from concept to high volume production. 

• Experience with alignment-intensive assembly methods and process controls used in fiber-coupled or optical device manufacturing. 

• Strong understanding of process development, qualification, troubleshooting, and transfer to manufacturing. 

• Ability to create clear process documentation and translate development work into repeatable production practices. 

• Experience collaborating with external equipment and materials partners to mature assembly solutions. 

• Strong foundation in yield analysis, reliability characterization, and process capability methodologies such as Cpk and SPC. 

Preferred Qualifications 

• Hands-on experience with active alignment systems for photonic or optical device assembly. 

• Hands-on experience with optical adhesives, encapsulants, and related material qualification. 

• Familiarity with optical performance verification, failure analysis, and process optimization. 

• Experience building high volume assembly tools, equipment qualification, and safe operating practices for optical assembly environments. 

Salary range is $133,200 to $185,000 depending on experience, level, and business need. This role may be eligible for discretionary bonus, incentives and benefits.