Sr. Prototyping Engineer

📍 Job Overview

Job Title: Sr. Prototyping Engineer

Company: Corning

Location: Keller, TX

Job Type: FULL_TIME

Category: Engineering / Manufacturing Operations

Date Posted: 2026-11-03T00:00:00

Experience Level: 5-10 Years

Remote Status: On-site

🚀 Role Summary

• This Senior Prototyping Engineer role is critical for the development and iteration of optical connectivity solutions within Corning's Optical Communications segment, focusing on hands-on prototype design, build, and process refinement.

• The position requires a strong understanding of mechanical assembly, fiber optic theory, and process development to translate product and customer needs into tangible prototypes for fiber optic networks.

• The engineer will drive technical execution for prototype builds, troubleshoot assembly and process issues, and provide crucial design-for-manufacturability feedback to product and technology teams.

• This role involves significant cross-functional collaboration with internal teams (Engineering, Quality, Supply Chain, Manufacturing) and external partners (suppliers, fabrication shops, contract manufacturers) to ensure successful prototype delivery and eventual technology transfer.

📝 Enhancement Note: The job description strongly implies a role within an R&D or New Product Introduction (NPI) engineering team, specifically supporting the development of physical optical networking components. The emphasis on "low-volume, development-oriented prototype line" and "transfer of mature solutions to Technology Teams or manufacturing operations" positions this as a crucial link between conceptual design and scalable production. The focus on fiber optic connectors and cable assemblies is central.

📈 Primary Responsibilities

• Design, build, and coordinate prototypes for optical connectivity solutions, specifically focusing on fiber optic connectors and cable assemblies for fiber optic networks.

• Develop comprehensive prototype build plans, including bills of materials (BOMs), work instructions, process documentation, and acceptance criteria.

• Lead the technical execution of prototype builds, providing direct guidance to technicians, troubleshooting build-related issues, and ensuring process repeatability and quality.

• Design, specify, and improve fixtures, tooling, equipment, and workstations to enhance quality, safety, ergonomics, and process consistency in prototype assembly.

• Analyze prototype build data, including yield, defect rates, and inspection results, to perform root-cause analysis and implement corrective actions.

• Provide critical design-for-manufacturability (DFM), design-for-assembly (DFA), and design-for-testability (DFT) feedback to product and technology development teams.

• Collaborate with global manufacturing teams to assess manufacturability and support the technology transfer process to production environments.

• Build and maintain strong relationships with internal subject matter experts and external suppliers, fabrication shops, tooling providers, and contract manufacturers.

• Document prototype results, capture customer feedback, identify technical risks, and potentially identify patentable innovations.

• Train technicians on new or revised processes, equipment, and documentation to ensure effective implementation and knowledge transfer.

• Ensure strict adherence to safety, Electrostatic Discharge (ESD), cleanliness, quality, and controlled document requirements throughout all prototyping activities.

📝 Enhancement Note: The responsibilities highlight a hands-on engineering role with a strong emphasis on process development and optimization within a prototype setting. The engineer is expected to be a technical leader on the shop floor, bridging design intent with practical execution and feeding insights back into the product development lifecycle. The scope extends to supplier management and technology transfer readiness.

🎓 Skills & Qualifications

Education:

• Bachelor of Science (BS) in Engineering, with a strong preference for Mechanical Engineering. Experience:

• Minimum of 5 years of experience in a development or experimental laboratory environment, with a focus on electrical/mechanical assembly and testing.

• Proven experience in developing, documenting, troubleshooting, and improving precision assembly or manufacturing processes. Required Skills:

• Demonstrated mechanical aptitude and a structured approach to problem-solving.

• Ability to interpret technical drawings, specifications, tolerances, bills of materials (BOMs), travelers, and test/inspection data.

• Strong technical communication skills, capable of clearly conveying complex ideas through written documentation, presentations, and direct interaction.

• Proficiency in managing multiple projects simultaneously, prioritizing tasks, and meeting established schedules and deliverables.

• Familiarity with fiber optic theory and its application in component design and assembly. Preferred Skills:

• Proficiency in CAD software, specifically Pro/ENGINEER (ProE) or Creo, for designing products or manufacturing processes.

• Ability to interpret and generate detailed technical drawings and schematics.

• Experience with discrete assembly processing and developing specific process parameters.

• Demonstrated project management experience, including the application of project management tools and methodologies.

• Proactive collaboration skills with a demonstrated ability to drive technical culture within an organization.

• Experience in collaborating with both internal and external designers and engineering teams.

📝 Enhancement Note: The requirement for Pro/ENGINEER or CREO is a critical technical skill for this role, indicating a need for direct involvement in CAD design for tooling, fixtures, and potentially prototype components. The emphasis on fiber optics, mechanical assembly, and process development points to a specialization within advanced manufacturing or product realization engineering.

📊 Process & Systems Portfolio Requirements

Portfolio Essentials:

• Demonstrate a track record of successfully translating product requirements into functional prototypes, showcasing the design, build, and validation phases.

• Provide examples of process improvement initiatives, detailing the problem, the implemented solution, and quantifiable results (e.g., yield improvement, cycle time reduction, defect rate decrease).

• Showcase experience with system implementation or modification for prototype lines, including fixture design, tooling specification, or equipment integration.

• Include case studies that illustrate the ROI or business impact of prototype development efforts, such as accelerating time-to-market or reducing development costs. Process Documentation:

• Exhibit proficiency in creating detailed work instructions, process flow diagrams, and standard operating procedures (SOPs) for prototype assembly and testing.

• Present examples of process documentation for new or revised assembly processes, highlighting clarity, completeness, and adherence to quality standards.

• Include documentation related to root-cause analysis and corrective action plans developed for prototype build issues.

📝 Enhancement Note: Candidates should prepare to showcase specific projects where they designed, built, and refined prototypes. This includes detailed documentation of the processes developed, the challenges encountered, and the solutions implemented. Quantifiable improvements and a clear understanding of DFM principles will be highly valued.

💵 Compensation & Benefits

Salary Range:

• $101,784.00 - $139,953.00 USD per year.

• The final starting salary will be determined based on factors such as geographic location, market demand, candidate experience, training, and education. Benefits:

• Retirement:

  • 100% company-paid pension benefit with fixed contributions that increase with career progression.
  • Matching contributions to a 401(k) savings plan, with total company retirement contributions potentially reaching 7-12% of pay (depending on age and service).

• Health & Wellness:

  • Comprehensive medical, dental, and vision insurance plans.
  • Paid parental leave and family-building support programs.
  • Fitness program and resources.
  • Company-paid life insurance and disability insurance.
  • Disease management programs.

• Time Off & Support:

  • Paid Time Off (PTO).
  • Employee Assistance Program (EAP) for personal and family support.

• Financial Incentives:

  • Company-wide bonuses and long-term incentives tied to business results.

  • Recognition program to celebrate exceptional contributions. Working Hours:

• Standard full-time work schedule, typically 40 hours per week.

📝 Enhancement Note: The salary range provided is competitive for a Senior Engineer role in the US, particularly in a specialized field like optical communications prototyping. The inclusion of a pension benefit is a significant differentiator, alongside a robust 401(k) matching program. The comprehensive benefits package covers health, wellness, and financial security, reflecting a strong commitment to employee well-being.

🎯 Team & Company Context

🏢 Company Culture

Industry:

• Materials Science, Glass, Ceramics, and Optical Communications. Corning is a global leader in innovation, with a rich history of developing groundbreaking materials and technologies that impact various sectors, including telecommunications, automotive, and life sciences. Company Size:

• Corning is a large, established corporation with tens of thousands of employees globally. This size offers stability, extensive resources, and opportunities for diverse career paths, while potentially having more structured processes. Founded:

• Corning was founded in 1851, giving it over 170 years of history and a deeply ingrained culture of innovation and resilience. This long history suggests a stable environment with a strong foundation in scientific discovery and engineering excellence. Team Structure:

• The role operates within the Optical Communications segment, likely within a New Product Introduction (NPI) or Advanced Development Engineering team.

• The Senior Prototyping Engineer will report into an Engineering Management structure and will work closely with a team of technicians, fellow engineers, and cross-functional stakeholders.

• Collaboration is expected across departments including Market Development, Product Line Management, Quality Assurance, Supply Chain, and potentially external suppliers and contract manufacturers. Methodology:

• The team likely employs a structured approach to product development, incorporating elements of Design for Excellence (DFX) principles, including Design for Manufacturability (DFM), Design for Assembly (DFA), and Design for Testability (DFT).

• A data-driven approach is evident through the emphasis on analyzing prototype build data, performing root-cause analysis, and implementing corrective actions.

• Process development and optimization are key methodologies, focusing on improving repeatability, yield, and efficiency within the prototype line. Company Website:

• https://www.corning.com/

📝 Enhancement Note: Corning's culture is deeply rooted in scientific innovation and a long-term vision, as evidenced by its history and the mention of a pension benefit. The Optical Communications segment is a significant part of their business, indicating a strategic focus and investment in this area. The role's position within this segment suggests working on cutting-edge technologies that enable global connectivity.

📈 Career & Growth Analysis

Operations Career Level:

• This role is classified as "Senior," indicating a level of expertise and autonomy beyond entry-level or mid-level engineering positions. It suggests a capacity for independent problem-solving, technical leadership within projects, and mentorship of junior engineers or technicians. The responsibilities imply a focus on hands-on execution and process improvement within a development context. Reporting Structure:

• The Senior Prototyping Engineer will likely report to an Engineering Manager or a Lead Engineer within the Optical Communications segment. They will collaborate closely with technicians on the prototype line, and interface with Product Managers, Market Development, Quality Engineers, Supply Chain specialists, and potentially external suppliers. Operations Impact:

• This role has a direct impact on the speed and quality of new optical connectivity product introductions. By efficiently building and refining prototypes, the engineer helps validate designs, identify manufacturing challenges early, and accelerate the transition of new technologies to mass production. This ultimately contributes to Corning's market leadership and revenue generation in the competitive optical communications space. Growth Opportunities:

• Technical Specialization: Deepen expertise in fiber optic technologies, advanced manufacturing processes, and prototyping techniques, potentially becoming a subject matter expert (SME) in specific areas like connector assembly or optical testing.

• Process Engineering Leadership: Transition into roles focused on scaling up manufacturing processes, leading NPI teams, or managing process improvement initiatives for mature product lines.

• Project Management: Develop project management skills further, leading larger or more complex prototype development programs, and potentially moving into dedicated Project Management roles.

• Cross-functional Mobility: Leverage experience to move into roles in Product Management, R&D, or Manufacturing Operations management within Corning's diverse business units.

📝 Enhancement Note: The "Senior" title suggests a career path that values deep technical contribution and process ownership. Growth opportunities are likely focused on increasing technical scope, leading larger initiatives, or moving into management roles within the engineering or operations functions.

🌐 Work Environment

Office Type:

• This is an on-site role, requiring the engineer to work within Corning's facilities, likely including office space for design and documentation, and a dedicated prototype laboratory or development line. Office Location(s):

• Keller, Texas. This location suggests proximity to potential customers, supply chain partners, or other Corning facilities within the region. Workspace Context:

• The workspace will involve a blend of collaborative office environments for design reviews and planning, and hands-on work within a prototype lab. This lab environment will be equipped with specialized tooling, assembly equipment, testing apparatus, and safety protocols (e.g., ESD controls).

• Access to advanced prototyping equipment, CAD software, and potentially metrology tools will be essential for performing job duties.

• Opportunities for close interaction with skilled technicians, fellow engineers, and cross-functional teams are inherent to the role, fostering a collaborative and problem-solving atmosphere. Work Schedule:

• A standard 40-hour work week is expected. However, given the nature of prototype development and project deadlines, there may be occasional requirements for extended hours or weekend work to meet critical project milestones.

📝 Enhancement Note: The on-site requirement is typical for hands-on engineering roles that involve direct interaction with equipment, materials, and laboratory personnel. The environment is expected to be dynamic, with a focus on practical execution and iterative problem-solving.

📄 Application & Portfolio Review Process

Interview Process:

• Initial Screening: HR or a recruiter will likely conduct an initial screening to assess basic qualifications, experience, and cultural fit.

• Technical Interview(s): Expect multiple rounds of interviews with engineering managers, lead engineers, and potentially team members. These interviews will focus on:

  • Technical Expertise: Deep dives into mechanical assembly, fiber optics, process development, CAD (ProE/CREO), and problem-solving methodologies. Be prepared to discuss specific projects and technical challenges.
  • Problem-Solving Scenarios: Hypothetical situations related to prototype builds, process failures, or design challenges will be presented to assess analytical and troubleshooting skills.
  • Project Experience: Detailed discussions about past projects, focusing on your specific contributions, challenges overcome, and outcomes achieved.

• Portfolio Review: A critical component will be the review of your professional portfolio. Be ready to present 2-3 key projects that highlight your prototyping, process development, and problem-solving capabilities.

• Behavioral/Cultural Fit Interview: Questions assessing teamwork, communication, adaptability, and alignment with Corning's values.

Portfolio Review Tips:

• Highlight Impact: For each project, clearly articulate the problem statement, your role and responsibilities, the solutions you developed, and the quantifiable results or impact achieved (e.g., improved yield by X%, reduced cycle time by Y%, enabled successful product launch).

• Showcase Process: Detail the processes you designed, documented, or improved. Include examples of work instructions, process flow diagrams, or tooling designs.

• Demonstrate Technical Skills: Include examples of CAD designs (fixtures, tooling), technical drawings, and analysis of test/inspection data. If possible, include visual aids like photos or diagrams of prototypes you worked on.

• Focus on DFM/DFA: Emphasize how you incorporated design-for-manufacturability and design-for-assembly principles into your prototype work.

• Structure: Organize your portfolio logically, perhaps by project type or skill area. Be prepared to walk the interviewer through your most relevant projects concisely.

Challenge Preparation:

• Process Design Exercise: You might be given a scenario and asked to outline a process for building a specific component or assembly, including necessary tooling, steps, and quality checks.

• Troubleshooting Scenario: Presented with a hypothetical failure in a prototype build, you may be asked to identify potential root causes and propose a troubleshooting plan.

• CAD Exercise: A basic CAD-related task or question about interpreting complex drawings might be included.

• Project Walkthrough: Be ready to present one of your portfolio projects in detail, simulating a project review.

📝 Enhancement Note: Candidates should prepare a portfolio that vividly illustrates their hands-on experience with prototyping, process development, and problem-solving, specifically within a manufacturing or R&D engineering context. The emphasis on CAD (ProE/CREO) means visual examples of designs will be highly advantageous.

🛠 Tools & Technology Stack

Primary Tools:

• CAD Software: Pro/ENGINEER (ProE) / CREO (essential for design of fixtures, tooling, and potentially prototype components).

• Prototyping Equipment: Various assembly stations, potentially including specialized machinery for fiber optic handling, termination, and testing.

• Measurement & Inspection Tools: Calipers, micrometers, optical comparators, microscopes, potentially CMMs or advanced optical inspection systems.

• Hand Tools & Power Tools: Standard and specialized tools for mechanical assembly and fabrication.

Analytics & Reporting:

• Data Analysis Software: Microsoft Excel (for data manipulation and analysis), potentially Minitab or similar statistical software for process analysis and DOE.

• Reporting Tools: Microsoft Office Suite (Word, PowerPoint) for technical documentation, reports, and presentations.

• Quality Data Systems: Familiarity with systems for tracking yield, defects, and inspection results.

CRM & Automation:

• While not a direct CRM role, understanding how prototype data feeds into product development pipelines and potentially ERP/MRP systems for material planning is beneficial.

• Document Control Systems: Experience with controlled document management for work instructions, SOPs, and engineering change notices.

📝 Enhancement Note: Proficiency in Pro/ENGINEER or CREO is explicitly required and will be a key focus during the evaluation. Familiarity with statistical analysis tools like Minitab would be a strong asset for process development and root-cause analysis.

👥 Team Culture & Values

Operations Values:

• Innovation: A core value at Corning, emphasizing pushing boundaries and developing novel solutions, which is directly applied in the prototyping process.

• Integrity: Upholding high ethical standards in all dealings, including accurate reporting of results and transparent communication.

• Teamwork: Strong emphasis on collaboration across diverse teams and functions to achieve common goals, particularly crucial in a cross-functional prototyping environment.

• Accountability: Taking ownership of projects, processes, and outcomes, ensuring that commitments are met and problems are resolved effectively.

• Excellence: Striving for the highest quality in design, execution, and process development, ensuring that prototypes meet stringent requirements.

Collaboration Style:

• Hands-on and Collaborative: The role requires active participation on the lab floor, working directly with technicians, while also engaging in frequent discussions and reviews with engineers, product managers, and other stakeholders.

• Data-Driven Decision Making: Decisions regarding process improvements and troubleshooting are expected to be supported by data analysis and root-cause investigation.

• Constructive Feedback: An environment where feedback is openly shared and utilized for continuous improvement of both products and processes.

• Cross-functional Integration: Seamless integration with design, manufacturing, quality, and supply chain teams to ensure a holistic approach to product development.

📝 Enhancement Note: The culture at Corning emphasizes a blend of deep technical expertise, a commitment to innovation, and strong collaborative practices. Candidates should be prepared to demonstrate how they embody these values in their work.

⚡ Challenges & Growth Opportunities

Challenges:

• Rapid Iteration: The fast-paced nature of prototype development requires quick adaptation to design changes and problem-solving under tight deadlines.

• Ambiguity in Early Stages: Prototypes often represent early-stage designs, meaning requirements may evolve, and unexpected technical hurdles are common.

• Balancing Speed and Quality: The need to deliver prototypes quickly while ensuring they are representative of production quality and reliable for testing.

• Managing External Dependencies: Coordinating with multiple external suppliers and contract manufacturers for specialized fabrication or components can be complex.

Learning & Development Opportunities:

• Advanced Fiber Optics Knowledge: Gaining deeper insights into the physics and practical applications of fiber optic components and systems.

• Prototyping and Manufacturing Technologies: Exposure to a wide range of cutting-edge prototyping techniques, tooling, and assembly equipment relevant to optical communications.

• Cross-functional Exposure: Understanding the entire product development lifecycle, from initial concept through to manufacturing transfer, by working closely with various departments.

• Process Optimization Skills: Developing advanced skills in Lean Manufacturing principles, Six Sigma methodologies, and statistical process control (SPC).

📝 Enhancement Note: This role offers significant opportunities for hands-on learning and skill development in a specialized, high-demand field. The challenges are inherent to the NPI and prototyping process, providing excellent growth potential for adaptable and driven engineers.

💡 Interview Preparation

Strategy Questions:

• "Describe a time you had to develop a prototype for a complex mechanical assembly with tight tolerances. What was your process, and what were the key challenges?" (Focus on structured approach, DFM, problem-solving)

• "How would you approach troubleshooting a new fiber optic connector assembly process that is exhibiting low yield or inconsistent performance?" (Highlight data analysis, root-cause analysis, process refinement)

• "Walk me through a project where you designed tooling or fixtures for a prototype build. What software did you use, and what considerations did you make for manufacturability?" (Showcase CAD skills, DFM, practical implementation)

• "Imagine you receive a new product design for a prototype build that has significant manufacturability concerns. How would you provide feedback to the design team, and what information would you need?" (Emphasize communication, collaboration, constructive feedback, data-backed arguments) Company & Culture Questions:

• "What do you know about Corning and its role in the optical communications industry?" (Research Corning's history, key products, and market position)

• "How do you approach collaboration with technicians and manufacturing personnel?" (Highlight respect, clear communication, hands-on support)

• "Describe a situation where you had to adapt your plans due to unexpected technical issues or design changes." (Demonstrate flexibility, problem-solving under pressure) Portfolio Presentation Strategy:

• STAR Method: For each project, structure your explanation using Situation, Task, Action, and Result.

• Visual Aids: Use diagrams, photos, or CAD renderings of prototypes, tooling, and processes.

• Quantify Impact: Always aim to provide measurable outcomes (e.g., "reduced assembly time by 15%," "improved optical performance by 5 dB," "identified critical defect that would have cost $X in production").

• Focus on Your Role: Clearly articulate what you did, what decisions you made, and what contributions you specifically made to the project's success.

• Conciseness: Be prepared to present your key projects within a set timeframe, focusing on the most relevant aspects for the Sr. Prototyping Engineer role.

📝 Enhancement Note: Interview preparation should focus on demonstrating a deep understanding of the prototyping lifecycle, strong mechanical and process engineering skills, proficiency in CAD, and excellent problem-solving abilities within a collaborative, fast-paced environment.

📌 Application Steps

To apply for this Sr. Prototyping Engineer position:

• Submit your application through the Corning Careers portal using the provided link.

• Tailor Your Resume: Customize your resume to highlight experience in prototyping, mechanical assembly, fiber optics, process development, CAD (ProE/CREO), and troubleshooting. Use keywords from the job description.

• Prepare Your Portfolio: Curate 2-3 of your most impactful projects that demonstrate your skills in prototype design, build, process improvement, and problem-solving. Ensure you can clearly articulate the challenges, your actions, and the results using the STAR method.

• Research Corning: Familiarize yourself with Corning's Optical Communications segment, its products, and its commitment to innovation. Understand the company's values and culture.

• Practice Interview Questions: Prepare answers to common technical, behavioral, and situational interview questions, focusing on demonstrating your problem-solving approach and hands-on capabilities. Rehearse your portfolio presentation.

⚠️ Important Notice: This enhanced job description includes AI-generated insights and operations industry-standard assumptions. All details should be verified directly with the hiring organization before making application decisions.