Sr Mechanical Design Engineer

FormFactor Inc.•Livermore, CA

About The Position

We are seeking a highly skilled and innovative Senior Mechanical Design Engineer to join our dynamic R&D team. In this role, you will lead the design, development, and optimization of advanced mechanical sub-components, including Micro-Electromechanical Systems (MEMS), complex thermo-mechanical systems, and precision sensors for high-performance MEMS probe cards. The ideal candidate will bring deep expertise in mechanical design, FEA analysis, and precision assembly, combined with hands-on experience in an R&D lab environment. This position requires strong problem-solving skills, the ability to work independently, and a passion for developing cutting-edge technologies.

Requirements

ANSYS Software
Employee Experience
Failure Analysis
Hands-On Learning
Manufacturing
Mechanical Engineering
Mechanical Engineering Design
Metrology
SolidWorks
Bachelor’s degree and a minimum of 2 years of related experience; or an advanced degree without experience; or equivalent work experience

Responsibilities

Design & Development: Create mechanical assemblies using 3D CAD software (e.g., SolidWorks, AutoCAD). Generate Bills of Materials (BOMs) and detailed engineering drawings.
Analysis & Simulation: Perform stress, strain, and thermal analysis on MEMS and related components. Conduct FEA simulations, interpret results, and prepare technical reports.
Manufacturing & Assembly: Apply DFM/DFA principles and perform statistical tolerance analysis. Implement geometric dimensioning and tolerancing (GD&T). Assemble probe cards and precision components in a clean lab environment.
Testing & Characterization: Execute metrology and characterization using microscopes, tribometers, probers, and other precision instruments. Collect and analyze experimental data, perform failure analysis, and recommend design improvements.
Collaboration & Leadership: Work closely with cross-functional teams including electrical engineers, process engineers, and manufacturing teams. Mentor junior engineers and contribute to continuous improvement initiatives.