Principal Mechanical Architect

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.

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.

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