Principal Mechanical Design Engineer

Principal Mechanical Design Engineer

Form Factor is seeking a Principal Mechanical Design Engineer to design, develop, integrate, and qualify precision mechanical systems for advanced semiconductor wafer probing and test equipment. As a senior individual contributor, you will lead complex mechanical design initiatives with significant technical autonomy, developing innovative solutions that enable highly accurate, reliable, and repeatable wafer test and measurement systems.

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. Drawing on P3-level expectations for independent technical leadership and complex engineering problem solving this position serves as a key contributor to next-generation product development and continuous improvement initiatives.

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…