Staff Mechanical Engineer

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Lumentum is seeking an experienced and highly motivated Staff Mechanical Engineer to lead the mechanical design and development of next-generation 1.6T and 2.4T optical transceiver modules for high-speed data center and AI applications.

The successful candidate will provide technical leadership across the entire product development lifecycle, from concept definition and mechanical architecture through detailed design, prototype build, qualification, mass production, and customer support. This role requires strong expertise in optical transceiver packaging, thermal management, mechanical reliability, tolerance analysis, and design for manufacturing.

Key Responsibilities:

• Lead the mechanical architecture and design of 1.6T and 2.4T optical transceiver modules, including OSFP, and other high-density form factors.
• Develop mechanical solutions for optical, electrical, thermal, and high-speed signal integrity requirements.
• Design and optimize module housings, cages, heat sinks, optical receptacles, pull-tabs, internal brackets, shields, gaskets, and sealing structures.
• Drive thermal design and analysis for high-power DSP, PIC, TIA, laser, and other optical and electronic components.
• Perform tolerance stack-up analysis and ensure proper fit, alignment, assembly, and optical coupling performance.
• Develop robust solutions for EMI shielding, environmental sealing, ESD protection, dust contamination prevention, and mechanical shock/vibration resistance.
• Lead DFM/DFA activities and collaborate closely with manufacturing, process engineering, quality, reliability, and suppliers.
• Define and execute mechanical verification and qualification plans, including dimensional inspection, thermal cycling, humidity testing, shock and vibration, insertion/withdrawal force, pull-tab durability, and other reliability tests.
• Analyze mechanical, thermal, and reliability failures, identify root causes, and implement corrective and preventive actions.
• Review and approve 2D drawings, 3D models, specifications, tolerance requirements, and engineering change documentation.
• Work closely with optical, electrical, RF, process, SCM, SQE, reliability, manufacturing team, and program management teams to resolve cross-functional issues.
• Provide technical guidance and mentorship to mechanical engineers and establish best design practices.
• Support customer technical reviews and communicate design concepts, risks, validation results, and mitigation plans clearly in English.
• Manage external suppliers and tooling partners to ensure component quality, schedule, and manufacturability.

Required Qualifications:

• Bachelor’s or Master’s degree in Mechanical Engineering, Mechatronics, Manufacturing Engineering, or a related field.
• 6+ years of experience in mechanical design and development of optical transceivers, high-speed communication modules, optoelectronic packages, or related precision electronic products.
• Demonstrated experience with high-density, high-power optical module development, preferably 800G, 1.6T, or 2.4T products.
• Strong knowledge of mechanical design, material selection, tolerance analysis, GD&T, thermal management, and reliability engineering.
• Proficiency with 3D CAD tools such as Creo, SolidWorks, NX, or equivalent, as well as 2D drawing and engineering documentation.
• Experience with plastic injection molding, die casting, CNC machining, stamping, sheet metal, adhesives, gaskets, and other relevant manufacturing processes.
• Experience leading complex projects from concept through mass production.
• Strong problem-solving, communication, presentation, and cross-functional collaboration skills.
• Ability to communicate effectively in written and spoken English.

Preferred Qualifications:

• Experience with OSFP, QSFP-DD, or other pluggable optical transceiver form factors.
• Experience with optical alignment, fiber-optic connector structures, TOSA/ROSA packaging, and optoelectronic assembly.
• Knowledge of EMI/EMC shielding, ESD control, environmental sealing, and contamination control.
• Experience with thermal simulation tools such as FloTHERM, Icepak, ANSYS, or equivalent.
• Experience with reliability testing, failure analysis, and statistical/tolerance analysis.
• Experience working with global customers and international suppliers.
• Experience in technical leadership, design reviews, and mentoring junior engineers.

Key Success Factors:

• Delivering mechanically robust and manufacturable designs for 1.6T and 2.4T optical modules.
• Achieving product performance, reliability, cost, and schedule targets.
• Establishing scalable mechanical design standards and best practices.
• Resolving complex cross-functional technical issues efficiently.
• Building strong collaboration with customers, suppliers, manufacturing sites, and internal engineering teams.

We are an equal opportunity employer and value diversity at our company.

We do not discriminate on the basis of race, religion, color, national origin, sex, gender, gender expression, sexual orientation, age, marital status, veteran status, or disability status.

We will ensure that individuals with disabilities are provided reasonable accommodation to participate in the job application or interview process, to perform essential job functions, and to receive other benefits and privileges of employment.

Please contact us to request accommodation.