Test Engineer, Manufacturing

About Sesame

Sesame believes in a future where computers are lifelike - with the ability to see, hear, and collaborate with us in ways that feel natural and human. With this vision, we're designing a new kind of computer, focused on making voice agents part of our daily lives. Our team brings together founders from Oculus and Ubiquity6, alongside proven leaders from Meta, Google, and Apple, with deep expertise spanning hardware and software. Join us in shaping a future where computers truly come alive.

About the Role

As a Manufacturing Test Engineer, you will be the technical expert responsible for developing, implementing, and optimizing manufacturing test solutions for our next-generation wearable devices. You will play a critical role in the entire product lifecycle, from initial design reviews to mass production, ensuring that every product leaving our manufacturing lines meets our rigorous quality and performance specifications. This role requires a blend of deep technical expertise, strategic thinking, and the ability to work effectively with large-scale contract manufacturers (CMs) and product development engineering across the globe.

Responsibilities:

• Test Strategy & Development: Architect and implement comprehensive manufacturing test strategies for new product introductions (NPIs), covering functional, parametric, and in-circuit testing for complex wearable devices.

• Test Fixture & Equipment Design: Design, develop, and qualify test fixtures, equipment, and software for various stages of the manufacturing process, from PCBA-level tests to final product assembly.

• Specialized Testing: Develop and optimize test solutions for specialized functions critical to our products, including:

  • Audio Testing: Acoustic test methodologies for speakers, microphones, and other audio components.

  • Camera & Imaging Testing: Calibration and functional tests for high-resolution cameras and optical systems.

  • RF & Wireless: Testing for wireless connectivity, including Bluetooth, Wi-Fi, and other RF protocols.

  • Sensors: Calibration and functional testing for various sensors (accelerometers, gyroscopes, biometric sensors).

• Data Analysis & Optimization: Utilize data analysis tools to automatically monitor test yields, identify trends, root cause failures, and flag production issues. Proactively drive continuous improvement to optimize test coverage, cycle time, and overall manufacturing efficiency.

• Collaboration with Contract Manufacturers (CMs): Act as the primary technical interface with our large-scale contract manufacturing partners. Train and support CM teams on test processes, troubleshoot issues on the factory floor, and ensure strict adherence to our specifications.

• Design for Testability (DFT): Partner with the product design and engineering teams during the development phase to influence product architecture and design for enhanced testability, manufacturability, and reliability.

• Documentation: Create and maintain detailed test specifications, process instructions, and engineering change notices (ECNs) to ensure clear communication and consistency across all manufacturing sites.

• Project Leadership: Lead and mentor junior engineers, providing technical guidance and expertise on complex test challenges. Manage third-party resources as required.

Required Qualifications:

• Deep expertise in developing test solutions for consumer electronics, including PCBA, FATP (Final Assembly, Test, and Pack), and system-level testing.

• Demonstrated experience with specialized testing:

  • Audio: Expertise with audio test equipment (e.g., Audio Precision, SoundCheck) and methodologies.

  • Camera: Experience with optical test benches, image quality analysis, and camera calibration.

  • RF: Experience with RF test equipment (e.g., spectrum analyzers, network analyzers) and wireless protocol testing.

  • Battery: Experience with battery testing methodologies, including charge/discharge cycling, impedance spectroscopy, and safety testing.

• Experience working directly and extensively with large-scale Contract Manufacturers (CMs), including overseas travel for factory support and new line bring-up.

• Strong knowledge of statistical process control (SPC), GR&R, and data analysis tools to drive yield improvements.

• Excellent problem-solving, communication, and interpersonal skills.

Preferred Qualifications:

• 10+ years of hands-on experience in manufacturing test engineering within the consumer electronics industry.

• Proven experience with wearables is highly preferred, including familiarity with the unique challenges of small form factor, high-density products.

• Proficiency in a programming language for test automation (e.g., Python, C#, LabVIEW).

• Demonstrated experience with specialized testing and calibration for eye tracking and vision.

• Bachelor's or Master's degree in Electrical Engineering, Mechanical Engineering, or a related field.

Sesame is committed to a workplace where everyone feels valued, respected, and empowered. We welcome all qualified applicants, embracing diversity in race, gender, identity, orientation, ability, and more. We provide reasonable accommodations for applicants with disabilities. Contact [email protected] for assistance.

Full-time Employee Benefits: 

• 401 (k) max employer match: 3.5% of compensation

• 100% employer-paid health, vision, and dental benefits for you and your dependents

• Unlimited PTO and sick time

• Flexible spending account with employer matching up to $1,650/year (medical FSA)

• Guardian Employee Assistance Program (EAP)

• Opportunity to share in the company's success with competitive stock options

Benefits do not apply to contingent/contract workers.