MEMS Process Integration Scientist

About the role

You will collaborate with a multidisciplinary team to pioneer next-generation MEMS and NEMS technologies that redefine industry standards for aerospace, automotive, and defense applications. This role owns the end-to-end integration of novel fabrication processes, ensuring that innovative laboratory discoveries transition seamlessly into scalable manufacturing workflows. You will lead the conception, design, and execution of complex experiments that push the boundaries of precision engineering and sensor technology. The position requires strategic systems-level thinking to solve intricate process interdependencies and remove bottlenecks in high-value development programs. You will guide technical strategy and influence long-term roadmaps for navigation-grade sensing platforms. This role emphasizes scientific originality, program ownership, and the mentorship of junior technical staff to build a robust innovation pipeline. You will secure external research initiatives and drive projects from initial concept through to real-world deployment.

Key facts

What you'll do

• Pioneer the development of advanced MEMS-enabled sensors and actuators for aerospace, automotive, and industrial applications, leading innovation that redefines industry standards.
• Integrate novel processes into scalable production workflows, applying systems-level thinking to ensure seamless transitions from research discovery to real-world implementation.
• Lead the complete design, fabrication, and testing lifecycle of MEMS devices and subsystems to meet stringent project requirements and performance specifications.
• Design and execute creative experiments to validate emerging MEMS technologies, solving complex challenges through innovative methodologies and exploratory research.
• Perform precision wafer inspections and metrology using advanced characterization tools to drive iterative improvements for both exploratory research and high-volume manufacturing processes.
• Manage critical project elements including timelines, deliverables, and cross-functional resources to ensure successful execution and impactful outcomes.
• Conceive, propose, and secure new research initiatives focused on MEMS, NEMS, and related enabling technologies that advance state-of-the-art navigation systems.
• Provide technical leadership and scientific originality to shape a portfolio of high-impact programs that bridge cutting-edge research with practical applications.
• Guide funded programs, influence technical strategy, and mentor junior staff to build capabilities and ensure project success across the organization.
• Develop and optimize process control monitors (PCM) for in-process verification, ensuring consistent yield and performance across fabrication batches.
• Modify mask layouts and utilize industry-standard CAD software such as L-Edit or Cadence to support device design and process integration activities.
• Write technical proposals to present innovative research and development concepts, securing funding and support for high-priority initiatives.
• Create detailed documentation for processes, experiments, and results to facilitate knowledge transfer and continuous improvement.
• Collaborate effectively with cross-functional teams, including design, packaging, test, and application engineering, to align on objectives and resolve integration challenges.
• Contribute to the advancement of first-of-a-kind navigation-grade components that combine reliability, precision, and affordability for transformative autonomous systems.

Requirements

• Hold a Ph.D. or Master's Degree in a physical science or engineering field with a minimum of 5 years of fabrication process experience in an R&D environment.
• Demonstrate proven expertise in process development, optimization, and design of experiments (DOE) with strong statistical data analysis skills to drive cutting-edge advancements.
• Thrive in a collaborative team environment by exhibiting strong verbal and written communication skills to enable effective cross-laboratory collaboration.
• Master end-to-end fabrication workflows, integrating diverse process recipes while addressing process interdependencies to achieve high-performance results.
• Possess hands-on experience with contact and stepper photolithography for precision patterning at micro and nanoscale dimensions.
• Demonstrate proficiency in wet and plasma dry etching techniques for material removal and surface modification across diverse substrates.
• Have advanced capability in high aspect ratio deep reactive ion etching (DRIE) for silicon, glass, and other MEMS-compatible materials.
• Apply chemical vapor deposition (CVD) methods to deposit thin films with controlled thickness, composition, and uniformity.
• Execute dielectric and metal deposition processes using physical vapor deposition and related techniques to form functional layers.
• Perform wafer bonding and vacuum encapsulation of microscale structures to enable robust packaging and environmental protection.
• Create and process sacrificial and structural layers, applying wet and dry release processes to achieve free-standing MEMS components.
• Utilize precision metrology tools such as optical and infrared microscopy, interferometric measurements, and scanning electron microscopy (SEM) with elemental analysis capabilities.
• Demonstrate expertise in designing and characterizing process control monitors (PCM) for in-process verification and yield optimization.
• Modify mask layouts and leverage CAD software such as L-Edit or Cadence for device design and process integration tasks.
• Write technical proposals to communicate innovative research concepts, objectives, and proposed experimental approaches to internal and external stakeholders.

Nice to have

• Hands-on micro-machining experience with advanced structuring and patterning techniques for precision component fabrication.

Practical notes

HRL Laboratories is an Equal Opportunity Employer.

All hours are full-time (40 hours per week).

This role is based in Malibu, California and requires presence in the lab.

Candidates must be eligible to work in the United States without sponsorship for this position.

This role is not eligible for visa sponsorship at this time.

Travel is not required for this role.

New consideration and interview processes will begin immediately and remain open until the position is filled.