Principal Mechanical Architect

FormFactor is seeking a highly experienced Principal Mechanical Architect to lead the mechanical architecture and design of next-generation semiconductor test and wafer probing platforms. As a senior technical contributor, you will be responsible for defining and driving system-level mechanical solutions for ultra-precision motion, wafer handling, chuck systems, positioning mechanisms, and integrated automation platforms.

This role serves as the mechanical architecture leader for complex electromechanical systems, partnering closely with Controls, Electrical, Software, Optical, Automation, Product Engineering, and Manufacturing teams to develop innovative solutions that meet demanding requirements for accuracy, repeatability, thermal stability, throughput, reliability, and scalability. The Principal Mechanical Architect independently leads complex engineering initiatives, influences product roadmaps, and provides technical leadership across multidisciplinary development teams.

Key Responsibilities:

Mechanical Architecture & System Design

• Define and own the mechanical architecture for advanced semiconductor wafer probing and test systems.

• Architect precision motion and positioning solutions, including X/Y/Z/θ stages, positioners, actuators, flexures, bearings, guide systems, and encoder technologies.

• Lead the design of wafer handling, wafer support, alignment, and chucking systems to achieve world-class precision and repeatability.

• Establish system-level mechanical performance requirements, specifications, and design targets.

Wafer Chuck & Positioning Systems

• Lead wafer chuck and chuck-control architecture, including wafer support, vacuum distribution, thermal management, Z-height control, planarity, and alignment mechanisms.

• Develop solutions that optimize probing accuracy, contact consistency, thermal performance, and wafer protection.

• Evaluate and improve chuck performance through modeling, testing, and experimental validation.

• Collaborate with controls teams to optimize force control, position control, and closed-loop performance.

Precision Motion & Mechatronics

• Design and optimize high-performance motion systems utilizing servo motors, linear motors, encoders, air bearings, precision guideways, and advanced mechanical mechanisms.

• Partner with Controls Engineering to develop integrated motion-control and feedback systems that meet demanding dynamic performance requirements.

• Support selection, integration, and qualification of sensors, actuators, and control hardware.

• Drive system-level optimization of motion profiles, positioning accuracy, repeatability, and throughput.

Structural, Thermal & Dynamic Analysis

• Analyze and resolve vibration, resonance, stiffness, thermal stability, and mechanical dynamic challenges.

• Perform and guide finite element analysis (FEA), modal analysis, tolerance analysis, and thermal-mechanical simulations.

• Develop design solutions that maximize precision while maintaining manufacturability, reliability, and cost effectiveness.

• Establish design methodologies and best practices for precision mechanical systems.

Product Development & Engineering Execution

• Lead mechanical architecture activities from concept development through prototype validation, qualification, release, and production ramp.

• Evaluate design tradeoffs involving performance, manufacturability, reliability, serviceability, scalability, and cost.

• Drive root cause investigations and resolution of complex technical issues affecting product performance or customer operations.

• Support New Product Introduction (NPI) programs and technology roadmaps.

System Integration & Cross-Functional Leadership

• Provide system-level leadership across mechanical, electrical, controls, software, optical, automation, and manufacturing disciplines.

• Drive technical decision-making through engineering analysis, experimental validation, and data-driven methodologies.

• Participate in design reviews and provide technical oversight on critical subsystem and system-level decisions.

• Collaborate with suppliers, development partners, and manufacturing teams to ensure successful implementation of designs.

Customer & Production Support

• Support customer installations, system qualification activities, factory acceptance testing, and production ramp efforts.

• Investigate and resolve complex field issues involving precision positioning, wafer handling, motion control, and mechanical performance.

• Partner with customers and internal teams to identify future technology requirements and performance improvements.

Technical Leadership

• Serve as a technical mentor and subject matter expert for mechanical engineering teams.

• Guide engineering standards, design practices, architecture reviews, and technology development initiatives.

• Influence long-term product architecture and engineering strategy through technical leadership and innovation.

• Lead complex engineering initiatives and cross-functional projects with significant business impact.

Preferred Qualifications & Experiences:

• Demonstrated expertise in precision motion systems, positioning stages, servo systems, actuators, encoders, and advanced mechanical mechanisms.

• Strong experience with semiconductor equipment, preferably wafer probers, precision test systems, or related capital equipment.

• Experience designing wafer chuck systems, wafer alignment methodologies, and wafer positioning architectures.

• Strong understanding of Mechanical dynamics, Structural stiffness, Vibration control, Thermal stability, Precision positioning systems, and Tolerance analysis.

• Experience integrating mechanical, electrical, sensor, controls, and software subsystems into complex electromechanical platforms.

• Proven ability to lead complex technical projects and influence engineering decisions across multiple disciplines.

• Experience with Chuck controllers, Force and position control systems, Closed-loop feedback architectures, Linear motors and servo systems, Air bearings and precision stages, Flexure-based mechanisms, and High-performance encoder technologies.

• Knowledge of vibration isolation systems, modal analysis, and dynamic modeling techniques.

• Experience with high-precision optical alignment, metrology, probing, or test systems.

• Customer-facing experience supporting installation, qualification, production ramp, and continuous improvement activities within semiconductor fabrication environments.

• Experience utilizing SolidWorks, Creo, FEA tools, MATLAB, Simulink, or equivalent engineering analysis software.