Principal Mechanical Design Engineer (Job Code 89774)

Lead and supervise the design, development, and testing of FormFactors proprietary mechanical components and systems. Collaborate closely with other engineers, project managers, and clients to ensure projects are completed on time and within budget. Provide information to project management and project controls, and manage mechanical work activities, including task assignments, progress monitoring, and quality assurance. Perform engineering work during the initial planning and design phases of projects and supports design, development, testing, and documentation. Generate BOM, handle ECOs, place POs for Probe Card (PC) components. Design, analyze and validate next generation cantilever/vertical MEMS probes. Design and fabricate modular mechanical kits to interface between different tester platforms. Perform and validate structural and thermal FEA simulations for contactors and tooling probes. Work on the assembly line and help technicians build first of the kind contactors and full probe cards. Perform development activities to improve the existing functionality of the contactors. Design, develop, and fabricate GDandT drawings for contactor parts and tooling fixtures used in Probe Card assembly and build prototypes. Develop and test an in-house automation tool to help build and scale probe cards.

Education Required: Masters degree or foreign equivalent in Mechanical Engineering or related field

Experience Required: 1 year of experience as Mechanical Engineer or related occupation

Special Requirements: Must have at least 1 year of prior work experience in each of the following:

1.

Designing and analyzing Micro-Electro-Mechanical Systems (MEMS)-based cantilever probes, and ensuring force-displacement compliance through iterative simulations and empirical validation using SolidWorks and AutoCAD.

2.

Mechanical design and development of Probe Cards (PCs) from concept through manufacturing release in adherence to customer requirements while collaborating cross-functionally with other teams.

3.

Performing non-linear static and transient structural and thermal FEA simulations for various fixtures and components of a Probe Card using ANSYS.

4.

3D Computer Aided Design (CAD) modeling using SolidWorks to develop complex mechanical assemblies, precision components, and creating detailed part and assembly drawings using Geometric Dimensioning and Tolerancing (GDandT) principles and ANSI Y14.5M standards.

5.

Design for Manufacture (DFM) and Design for Assembly (DFA) principles, including tolerance stack-up analysis and robust assembly fit through Datum Reference Frames (DRFs) and Feature Control Frames (FCFs).

6.

Automating FEA workflows using Python with ANSYS scripting interface to improve simulation efficiency for iterative product design cycles.

7.

Generating multi-level Bill of Materials (BOMs), managing Engineering Change Orders (ECOs), and handling part lifecycle management through PLM platforms using Agile PLM.

Email resume to ... specifying job code 89774. EOE.