Manufacturing Engineering

Assembly and integration of complex scientific instruments and systems is a core area of expertise for the Manufacturing Engineering Department, with deep experience working on many different projects, including particle accelerators and detectors. Capabilities include precision assembly, vacuum systems, magnets, detector systems, and cleanroom work.

The Engineering Division supports design for manufacturability through close integration of design, fabrication, metrology, and assembly, enabling early feedback and rapid iteration on projects. Manufacturing engineers and machining experts advise mechanical engineering design staff about manufacturability and perform CAD and model quality checks, all of which help to ensure designs meet strict performance requirements and, at the same time, are able to be built as efficiently as possible.

Our team specializes in designing, prototyping, and fabricating specialized equipment for scientific research. Our capabilities extend to traditional machining at large and small scales, ultra-precision machining, additive manufacturing, welding, abrasive water jet machining, electrical discharge machining, powder coating, ultra-high vacuum cleaning, and more. Engineers, machinists, and technicians at the Lab focus on collaborative production of one-of-a-kind scientific instrumentation. 

Much of the work accomplished at the Lab requires sourcing one-of-a-kind or highly specialized equipment from outside vendors. Engineering has strong technical procurement and vendor management capabilities, with specialized teams that handle the acquisition of complex scientific and custom-fabricated items. Our technical procurement experts are active through the requisition lifecycle, including preparation of technical content in requests for proposals (RFPs), vendor selection, monitoring vendor quality assurance, tracking vendor performance, regular vendor visits, and ensuring compliance with technical, safety, and regulatory requirements.

Engineering has a robust set of capabilities in precision measurement, alignment, survey, and testing. The Survey and Alignment Group is responsible for the accurate positioning of accelerator and instrumentation components using precision surveying techniques and engineering methodologies. This group utilizes state-of-the-art tools such as laser trackers, laser scanning and interferometry, digital levels, and ground-penetrating radar.

QA is integrated into engineering, procurement, and project management processes at the Lab, ensuring performance requirements and compliance with DOE standards. Capabilities include vendor oversight, inspection and testing, nonconformance tracking, and embedded QA support. Berkeley Lab has a culture of continuous improvement that is supported by regular assessments, audits, and corrective action, with formal procedures for document control, verification, and risk mitigation. The Engineering Division also has a strict process for managing nonconformances—when defined requirements, performance metrics, or standards are not met. Nonconformances are tracked through an issues management system, enforcing corrective actions, capturing lessons learned, and ensuring compliance with DOE and regulatory requirements.