This role is responsible for the design and optimization of precision positioning systems, wafer handling mechanisms, probe interfaces, and motion-controlled assemblies that support leading-edge semiconductor technologies. The Principal Mechanical Design Engineer will collaborate closely with electrical, controls, systems, manufacturing, and product development teams to deliver robust mechanical solutions that meet demanding performance, reliability, and manufacturability requirements.
Key Responsibilities
Mechanical System Design & Development
Lead the design and development of complex mechanical components, assemblies, and subsystems for semiconductor wafer probing and test equipment.
Design precision mechanical systems including positioning stages, motion platforms, alignment mechanisms, positioners, and structural assemblies.
Develop innovative mechanical solutions that balance performance, reliability, manufacturability, cost, and serviceability.
Drive mechanical designs from concept through prototype, validation, production release, and lifecycle support.
Precision Motion & Wafer Handling Systems
Design and support wafer chuck, wafer handling, wafer alignment, and probe positioning systems.
Integrate precision motion components including motors, actuators, encoders, sensors, bearings, and linear guide systems.
Optimize system performance to achieve stringent requirements for accuracy, repeatability, stability, and throughput.
Evaluate and improve precision mechanisms supporting advanced semiconductor testing applications.
Analysis & Engineering Validation
Perform detailed engineering analysis including tolerance stack-ups, structural analysis, finite element analysis (FEA), thermal modeling, and vibration analysis.
Conduct design trade-off studies to optimize mechanical performance and reliability.
Develop test plans, validation methodologies, and acceptance criteria for mechanical systems and subsystems.
Evaluate prototype performance and implement design improvements based on data-driven analysis.
System Integration & Cross-Functional Collaboration
Partner closely with controls, electrical, systems, software, and manufacturing engineers to integrate motion control, automation, and hardware solutions.
Support system-level integration, debugging, and qualification activities.
Participate in architecture reviews, design reviews, risk assessments, and technical feasibility evaluations.
Collaborate with suppliers and manufacturing teams to ensure successful product realization and scalability.
Prototype Development & Testing
Build, assemble, and evaluate mechanical prototypes and engineering development units.
Conduct testing to verify system performance, precision, repeatability, stiffness, thermal stability, and reliability.
Analyze experimental results and implement corrective actions to resolve performance gaps.
Support engineering verification, design qualification, and product release activities.
Troubleshooting & Continuous Improvement
Lead troubleshooting efforts involving mechanical, thermal, alignment, vibration, and motion-control related issues.
Perform root cause analysis and implement corrective and preventive actions.
Identify opportunities for product improvements, cost reductions, reliability enhancements, and manufacturing efficiencies.
Drive continuous improvement initiatives throughout the product lifecycle.
Documentation & Technical Leadership
Create and maintain detailed engineering documentation including CAD models, drawings, specifications, bills of materials, test plans, reports, and engineering change documentation.
Apply GD&T principles and engineering standards to ensure product quality and manufacturability.
Mentor junior engineers and provide technical guidance on mechanical design methodologies and best practices.
Serve as a key technical contributor on complex development projects and strategic engineering initiatives.
Preferred Qualifications & Experiences
BS/MS in Mechanical Engineering, Mechatronics, Robotics, or related engineering field.
Experience with precision mechanical systems, automation, semiconductor equipment, robotics, or similar high-performance equipment.
Strong mechanical design experience using 3D CAD and engineering drawings.
Experience with GD&T, tolerance analysis, FEA, and mechanical system analysis.
Strong problem-solving and analytical skills.
Ability to work effectively in a cross-functional engineering environment.
Skills
3D Cad Modeling, Mechanical Design, SolidWorks, Vibration Analysis
Education & Experience
Minimum of 5 years of related experience with a Bachelor’s degree; or 3 years and a Master’s degree; or a PhD without experience; or equivalent work | Required
Pay Range
$94,100.00 - $123,480.00
Pay Range Explained
This role in Beaverton, Oregon pays between $94,100.00 and $123,480.00 per year, depending on your experience, skills, and background. Pay may vary in other locations. We offer a full benefits package, including medical, dental, vision, life insurance, disability coverage, a 401(k) with company match, employee stock purchase plan (ESPP), and paid time off. You’ll also be eligible for quarterly profit-sharing bonuses and flexible spending or savings accounts.
Equal Employment Opportunity Statement
FormFactor is an equal opportunity employer. FormFactor complies with all national, state, and local laws that seek to promote equal opportunities for any applicant or employee without regard to age, race, color, gender, gender identity/expression, national origin, sexual orientation, religion, disability, marital status, pregnancy or related condition, military service, or any other legally protected characteristics. These protections apply to all aspects of employment, including but not limited to, recruitment, hiring, training, promotions, and compensation.
For roles that are designated as remote-eligible, employees cannot be located in: AL, AK, AR, DE, GA, HI, IL, IA, KY, LA, ME, MD, MS, MO, NE, NV, NJ, NM, ND, OK, PA, RI, SC, SD, TN, WV, WI, WY. This list is continuously evolving and being updated, please check back with us if the state you live in is on the exclusion list. A role is remote-eligible only when it is listed as "Remote" in the job location.
