Senior Opto-Mechanical Engineer

Senior Opto-Mechanical Engineer

Location: Bolton, MA (hybrid eligible)

Role Summary

Headwall is seeking a versatile Opto-Mechanical Engineer to develop and support precision optical instruments used in hyperspectral imaging applications. This role bridges optical and mechanical engineering, translating optical system requirements and designs into robust, manufacturable products.

The ideal candidate is a strong opto-mechanical designer of precision imaging systems with practical proficiency in optical design and analysis tools such as OpticStudio. The role requires the ability to understand and evaluate optical designs, perform system analysis and tolerancing, identify performance trades, and work effectively across optical, mechanical, manufacturing and applications engineering.

Key Responsibilities

• Develop opto-mechanical architectures and detailed designs for hyperspectral imaging systems, spectrometers, foreoptics, and related optical assemblies using SolidWorks or equivalent 3D CAD tools.
• Use OpticStudio to interpret, analyze, and modify optical designs, including tolerance, sensitivity, and performance analyses.
• Translate optical requirements and prescriptions into practical mechanical designs, addressing optical mounting, alignment, thermal management, datum structures, and tolerance allocation.
• Evaluate system-level design trades across optical performance, mechanical constraints, manufacturability, cost, and schedule.
• Support new product development from concept and feasibility through design reviews, prototyping, qualification, and production release.
• Develop optical and opto-mechanical specifications, drawings, test methods, fixtures, and acceptance criteria.
• Participate hands-on in prototype assembly, alignment, testing, troubleshooting, and first article builds.
• Work with manufacturing engineering and production to apply DFM/DFA principles and transition designs into reliable, repeatable production.
• Support sustaining engineering and troubleshooting of existing products, including optical and mechanical performance issues.
• Collaborate with customers, product management, applications engineering, suppliers, and other engineering disciplines to translate requirements into practical engineering solutions.

Required Qualifications

• BS in Optical Engineering, Mechanical Engineering, Physics or a related engineering discipline; advanced degree a plus.
• 5+ years of experience developing precision optical or opto-mechanical systems.
• Strong experience designing precision mechanical assemblies using SolidWorks or similar parametric CAD software.
• Practical proficiency with OpticStudio or equivalent optical design software, including the ability to understand existing optical prescriptions and evaluate system performance and tolerances.
• Strong understanding of optical alignment, tolerancing, mounting techniques and the interaction between optical and mechanical tolerances.
• Proficient in the use of GD&T methods in dimensioning and tolerancing mechanical drawings.
• Hands-on experience assembling, aligning, testing and troubleshooting optical systems.
• Experience taking hardware through prototype, qualification and production release.
• Working knowledge of optical fabrication, mechanical fabrication and inspection methods.
• Ability to work effectively across optical, mechanical, electrical, software, manufacturing and applications engineering disciplines.

Desired Experience

• Experience with hyperspectral / imaging spectrometer systems, diffraction gratings, and/or broadband optical systems
• Experience designing & mounting metal mirrors.
• Stray-light, SNR, throughput or related optical system analysis.
• Environmental and thermal analysis of precision optical assemblies.
• Optical component specification and applicable ISO/MIL optical drawing standards.
• MATLAB, Python or similar engineering analysis tools.
• Experience developing optical test fixtures and production alignment/test methods.
• Experience working within a smaller, agile organization.

Work Environment

This position works in office, engineering laboratory, and manufacturing environments. Laboratory work may involve optical and electronic equipment, lasers, hand tools, mechanical assemblies, and chemicals commonly used in engineering labs. Appropriate safety procedures and PPE must be followed.

The position requires computer and bench work, handling of small components and precision equipment, and occasional lifting of equipment or assemblies up to 30 pounds. Reasonable accommodations may be made to enable individuals with disabilities to perform essential job functions.

Other

Headwall is an Equal Opportunity Affirmative Action Employer and does not discriminate on the basis of race, religion, color, sex, gender identity, sexual orientation, age, non-disqualifying physical or mental disability, national origin, veteran status, or any other basis covered by appropriate law. All employment is decided on the basis of qualifications, merit, and business need. We are an official Affirmative Action Program employer. Headwall encourages any United States citizen and others who are authorized to work in the United States to apply for these positions. Due to export restrictions, the candidate must be a US Citizen or Permanent Resident.

No agencies, please.