Fabrication Shop Manager

About the Role

Sesame AI is building deeply integrated hardware + AI products and is opening a fabrication shop and prototype line in Bellevue, WA. We're looking for a Fabrication Shop Manager to build it, staff it, and run it.

You'll develop and prove out the manufacturing processes our products depend on and build them into a repeatable proto line. You'll work closely with mechanical, electrical, manufacturing, and industrial design engineering to turn concepts into production-representative builds that inform product and DFM decisions.

The ideal candidate has run a machine shop or pilot line, is fluent in CNC and joining processes for plastics and metals, and cares as much about how a part gets made as how it looks when it's done.

Responsibilities

Shop Design & Build

• Work with the team to design a functional & flexible space to meet current & future proto needs
• Drive detailed layout equipment selection and procurement, utilities, safety, and IT
• Manage build & equipment install and commissioning

Manufacturing Process Development

• Develop, characterize, and document processes for CNC machining (multi-axis, metal and plastic)
• Develop jigs, fixtures, and work instructions that make each process repeatable
• Use metrology and CT scanning to qualify parts and processes against drawings and GD&T.

Shop Operations & Team Leadership

• Run the shop: scheduling, job tracking, equipment uptime and maintenance, consumables, inventory, and budget.
• Hire, manage, and grow CNC engineers and operators, technicians, and shop support staff.
• Set priorities across concurrent programs and keep turnaround times predictable for engineering.
• Own shop safety: training, PPE, machine guarding, lockout/tagout, and hazardous materials handling.
• Source, qualify, and manage external CNC, molding, PCBA, and specialty fabrication vendors; apply a clear in-house vs. vendor framework based on critical path, IP sensitivity, and volume.

Engineering Partnership & Quality Judgment

• Review designs early for manufacturability and flag process risk before it reaches a build.
• Evaluate builds for fit, finish, and dimensional quality and document results with photos, measurements, and structured feedback.
• Coordinate with engineering leads to align proto line schedules with program milestones.

Required Qualifications

• 12+ years in prototype machine shop, pilot line, or manufacturing engineering roles, with at least 3 years managing a shop or team.
• Hands-on mastery of CNC machining (setup, fixturing, CAM basics) and at least one joining or forming process such as ultrasonic welding, thermoforming, or laser processing.
• Experience standing up or expanding a shop or line: equipment selection, layout, procurement, and commissioning.
• Strong command of mechanical drawings, GD&T, metrology, and common engineering materials (plastics, metals, composites).
• Proven ability to hire and lead technicians and operators and to manage vendors to schedule and budget.
• Clear written and verbal communication; comfortable presenting designs & data to cross-functional teams.
• Safety-first mindset with experience owning shop safety programs.
• On-site role in Bellevue, WA; daily hands-on presence in the shop.

Preferred Qualifications

• Experience with eyewear, wearables, or other small consumer devices with tight cosmetic and dimensional requirements.
• Experience with Mastercam, Hypermill, or equivalent CAM; Fusion 360 or SolidWorks for fixture design.
• Familiarity with CT scanning and optical metrology (Lumafield, OGP, or similar).
• Experience with injection-molded plastics, or cast and machined metal cosmetic parts.
• Experience at a fast-paced startup or early-stage hardware company.

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.