Sr Staff Mechanical Design Engineer

Forming Our Future together

FormFactor, Inc. (NASDAQ: FORM), is a leading provider of essential test and measurement technologies along the full semiconductor product life cycle — from characterization, modeling, reliability, and design de-bug, to qualification and production test. Semiconductor companies rely upon FormFactor’s products and services to accelerate profitability by optimizing device performance and advancing yield knowledge. The company serves customers through its network of facilities in Asia, Europe, and North America.

Rooted in our core values — Focus on the Customer, Ownership & Accountability, Respectfully & Effectively Communicate, and Motivate & Develop People — we foster an environment where diverse perspectives are not only welcomed but celebrated. Everyone can make an impact here. Whether it's improving products, supporting customers, or positively influencing peers and the community, the contributions of our people matter.

Shift:

The regular hours for this position are day shift.

Job Description:

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.

Key Responsibilities:

Technical Leadership & Engineering Execution

• 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.

Problem Solving & Analysis

• 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.

Design & Documentation

• 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.

Cross-Functional & Customer Collaboration

• 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.

Continuous Improvement

• 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.

Skills:

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

Education & Experience:

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 | Required

Pay Range:

$163,400.00 - $214,410.00

Pay Range Explained:

This role in Livermore, California pays between $163,400.00 and $214,410.00 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.