Sr Staff Mechanical Design Engineer

FormFactor Inc.•Livermore, CA

1d•Onsite

About The Position

The Sr Staff Mechanical Design Engineer is a senior technical leader responsible for defining, developing, and delivering innovative mechanical design solutions for highly complex products and systems. Operating with a high degree of autonomy, this role provides deep technical expertise, leads critical engineering initiatives, and drives architectural decisions that impact product performance, reliability, and manufacturability. The role partners closely with R&D, manufacturing, quality, and customers to solve complex engineering challenges and advance next-generation probe card technologies.

Requirements

Minimum of 12 years of related experience with a Bachelor’s degree; or 8 years and a Master’s degree; or a PhD with 5 years experience; or equivalent experience
3D Modeling
Agile Systems
Autodesk AutoCAD
Communication
Data Analysis
Error Budgets
FEA Software
Geometric Dimensioning And Tolerancing (GD&T)
MATLAB
Mechanical Design
Precision Engineering
Precision Machine Design
Problem Solving
Product Development
Python (Programming Language)
SolidWorks
Thermal Design

Responsibilities

Independently develop and implement concepts to resolve significantly complex product issues and deliver robust engineering solutions.
Serve as a technical lead on major engineering projects, spearheading research and development of new technologies, methods, and design approaches.
Lead probe card mechanical design and architecture development, defining system-level strategies and long-term technical direction.
Specify and perform significantly complex mechanical analyses, including structural, thermal, and tolerance studies.
Identify, troubleshoot, and resolve a wide range of significantly complex engineering problems, often involving novel or ambiguous technical challenges.
Define and drive internal probe characterization and reliability testing; coordinate data review, root-cause analysis, and failure investigations.
Translate analytical results into design improvements and actionable engineering recommendations.
Specify, develop, design, and modify complex engineering layouts, schematics, detailed drawings, and technical specifications.
Specify, review, and approve engineering documentation, standards, and processes to ensure accuracy, consistency, and compliance.
Ensure designs meet performance, reliability, cost, and manufacturability requirements.
Interface with internal stakeholders and external customers on significantly complex engineering issues to meet technical commitments and delivery objectives.
Collaborate with manufacturing to build prototypes, alpha, and beta probe cards, supporting design-for-manufacturing and design-for-assembly initiatives.
Support manufacturing and field service teams by providing expert-level technical guidance on probe card issues and escalations.
Drive product and process continuous improvement initiatives focused on quality, cost, yield, and reliability.
Influence best practices, mentor senior engineers, and contribute to the development of engineering capability across the organization.