Key Responsibilities and Required Skills for Optical Manufacturing Technician

🎯 Role Definition

The Optical Manufacturing Technician is responsible for fabricating, assembling, testing, and inspecting precision optical elements and subassemblies used in lenses, mirrors, laser systems, sensors, and scientific instruments. This role requires hands-on experience with optical polishing, grinding, lapping, interferometric metrology, thin‑film coatings, and cleanroom assembly. The technician applies process control, documentation, and quality standards (ISO 9001, AS9100 preferred) to deliver repeatable, high-yield optics manufacturing that meets tight specifications for surface figure, surface roughness, radius of curvature, centration, and coating performance.

📈 Career Progression

Typical Career Path

Entry Point From:

Optical Assembler / Production Assembler with experience in optics or precision components
Machine Operator or CNC Technician transitioning into optical fabrication
Vocational/Technical graduate with coursework in optics, precision machining, or applied physics

Advancement To:

Senior Optical Technician / Lead Optical Fabricator
Optical Process Engineer / Manufacturing Engineer (optics)
Metrology Technician / Optical Quality Engineer
Production Supervisor or Operations Manager in optics manufacturing

Lateral Moves:

Thin‑Film Coating Technician or Vacuum Coating Specialist
CNC Programmer / Machinist with optics specialization
Optical Systems Assembler or Integration Technician

Core Responsibilities

Primary Functions

Execute precision grinding, polishing, and lapping of optical glass and crystalline substrates to achieve specified surface figure (e.g., λ/10) and surface roughness (Ra/nm), following work instructions and process recipes.
Perform interferometric testing using phase-shifting and Fizeau interferometers to measure wavefront error, surface figure, and transmitted wavefront; interpret fringe maps and create corrective actions.
Operate and program CNC optic generators, CNC polishing platforms, and multi-axis machining centers for aspheric and spherical surfaces; verify toolpaths and part setup for repeatable results.
Diamond-turn metal and single-crystal optics on ultra-precision lathes to produce high-accuracy freeform and rotationally symmetric surfaces; inspect tool wear and adjust parameters for optimal finish.
Conduct surface roughness and texture measurements using optical or stylus profilometers and ensure parts meet Ra/Rq specifications as documented in work orders.
Prepare and perform optical cleaning, chemical etching, and contamination control procedures in ISO-class cleanrooms; apply best practices for particle prevention and handling of hygroscopic or sensitive materials.
Load, monitor, and qualify vacuum coating runs (PVD, sputtering, e-beam) for AR, HR, and beam-splitter thin-film stacks; validate thickness, reflectance/transmittance, and adhesion per coating recipes.
Align, assemble, and bond multi-element lens systems and opto-mechanical assemblies using precision jigs, optical benches, autocollimators, and laser alignment tools; perform torque-controlled fastening and adhesive cure cycles.
Inspect incoming raw materials and vendor parts against purchase specifications using visual inspection, CMM, calipers, micrometers, and optical comparators; quarantine non-conforming material and document findings.
Execute final inspection and acceptance testing of finished optical components and assemblies including spectral testing, back-focal length verification, MTF/PSF measurements, and environmental screening where required.
Maintain accurate production records, process travelers, inspection reports, and calibration logs in the manufacturing execution system (MES) or ERP; ensure traceability from raw material lot to finished part.
Develop and revise standard operating procedures (SOPs), manufacturing work instructions, and process control plans to improve yield and reduce variability in optical fabrication processes.
Troubleshoot process and equipment issues (polishing pads, compounds, fixture alignment, coating instability) and implement corrective actions in collaboration with engineering and maintenance teams.
Perform preventative maintenance, calibration, and basic repair on optical fabrication equipment including polishers, grinders, interferometers, and vacuum systems, escalating to vendors as needed.
Use statistical process control (SPC) tools and measurement system analysis (MSA) to monitor critical dimensions and optical performance metrics and to drive continuous improvement projects.
Fabricate and inspect precision mechanical components and opto-mechanical mounts using mills and lathes to support custom fixtures and prototypes for optical assemblies.
Execute delicate assembly operations such as UV- or heat-cure adhesive bonding, index-matching gel application, and o-ring seal installations while maintaining optical axis integrity and cleanliness.
Participate in design-for-manufacturability (DFM) and design-for-testability (DFT) reviews with engineering to optimize optical component designs for manufacturability, assembly, and test.
Train and mentor junior technicians in best practices for optics handling, polishing techniques, interferometry interpretation, and cleanroom discipline to raise overall team capability.
Support qualification activities for new processes, tools, or materials including process validation, capability studies (Cp/Cpk), and documentation for quality management system audits.
Collaborate with procurement and vendors to evaluate subcontracted optics services, qualify external suppliers, and manage vendor quality performance and corrective action plans.
Prepare shipping packaging, protective carriers, and ESD/moisture control measures for delicate optics; coordinate with logistics for safe transport and receipt of high-value components.

Secondary Functions

Assist engineering teams with prototyping, optical test setups, and R&D experiments to validate new optical designs and processes.
Provide input to cost estimation and production planning by documenting cycle times, scrap rates, and tooling requirements for optical parts.
Participate in cross-functional problem-solving (8D, root cause analysis) when field or in-process failures occur, contributing hands-on data and test results.
Maintain inventory of polishing media, slurries, pads, adhesives, and consumables; recommend process changes to reduce waste and cost.
Support calibration schedules by coordinating external calibration services and maintaining equipment calibration status in the CMMS.
Contribute to workplace safety and compliance efforts through hazard reporting, training refreshers, and adherence to cleanroom and hazardous-material protocols.

Required Skills & Competencies

Hard Skills (Technical)

Optical Metrology: interferometry (Fizeau, Twyman-Green), autocollimation, MTF/PSF measurement, profilometry, and spectrophotometry.
Optical Fabrication: precision grinding, pitch and polyurethane polishing, lapping, beveling, chamfering, and centrosymmetric polishing techniques.
CNC & Diamond-Turning: operation and programming of CNC optic generators, ultra-precision diamond turning machines, and multi-axis machining centers.
Thin-Film Coatings: familiarity with PVD/sputter/e-beam processes, witness sample analysis, and coating specification interpretation for AR and HR coatings.
Cleanroom Protocols: ISO-class cleanroom behavior, particle control, contamination mitigation, and clean handling of optics and assemblies.
Mechanical Measurement: use of CMMs, micrometers, calipers, optical comparators, gauge blocks, and custom fixtures for dimensional and form verification.
Metrology Software & Data: experience with data capture, fringe analysis software, SPC packages, and reporting measurement uncertainty and capability.
Materials & Adhesives: knowledge of optical glasses, crystals (e.g., fused silica, BK7, CaF2), mechanical properties, adhesives (epoxies, UV cure), and thermal cure processes.
Quality Systems: experience with ISO 9001 / AS9100 processes, NCRs, CAPA, corrective actions, and documentation control.
Soldering & Bonding: precision soldering, adhesive dispensing, index matching, and controlled cure processes for sensitive optical assemblies.

Soft Skills

Attention to detail and strong manual dexterity for precision handling and assembly of delicate optical components.
Analytical problem-solving skills with a methodical approach to troubleshooting process and measurement deviations.
Clear written and verbal communication for documenting procedures, reporting inspection results, and interacting with cross-functional teams.
Ability to prioritize tasks in a fast-paced production or prototype environment while maintaining high quality and schedule adherence.
Teamwork and mentorship aptitude to train junior staff and collaborate with engineering, quality, and procurement.
Continuous improvement mindset with openness to Kaizen, lean manufacturing practices, and data-driven process optimization.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED with technical/vocational training in optics, precision machining, or related trades.

Preferred Education:

Associate degree or certificate in Optical Technology, Precision Machining, Manufacturing Technology, Applied Physics, or Engineering Technology.
Bachelor’s degree in Optical Engineering, Mechanical Engineering, or related STEM field for advanced roles.

Relevant Fields of Study:

Optical Engineering / Optical Technology
Precision Machining / Manufacturing Technology
Mechanical Engineering Technology
Applied Physics / Materials Science

Experience Requirements

Typical Experience Range: 2–7 years in optics manufacturing, precision machining, or related manufacturing roles.

Preferred:

3+ years hands-on experience in optical fabrication and metrology, with demonstrated competence in interferometry and polishing.
Prior experience working in a cleanroom environment and with thin-film coating processes is highly desirable.