Microfabrication & Molding Process Engineer

Role details

Microfabrication & Molding - Process Engineer Responsibilities

• Develop, optimize, and validate precision microfabrication, micro-hole formation, molding, casting, and advanced materials processes for semiconductor, microelectronics, advanced packaging, PCB/substrate, soft wearable, and mOSAT-related applications.
• Support small-hole and micro-feature formation using laser drilling, micro-CNC drilling, micro-machining, EDM, mechanical drilling, controlled-depth drilling, via formation, and related advanced manufacturing methods.
• Design and optimize mold cases, mold tools, fixtures, coupons, and custom hardware using CAD, CFD, mold-flow analysis, FEA, prototyping, and design-for-manufacturability principles.
• Operate and improve compression molding, transfer molding, liquid injection molding, micro-molding, casting, and related polymer or elastomer processing systems.
• Work with silicone, epoxy molding compound, polymers, elastomers, metalized substrates, advanced electronic materials, and semiconductor packaging materials to support material selection, process compatibility, and sample development.
• Plan and execute DOE, feasibility trials, parameter studies, process capability studies, prototype builds, analytical testing, metrology, dimensional inspection, microscopy, and related characterization activities.
• Create and maintain process documentation, including equipment recipes, mold setup sheets, process parameters, travelers, SOPs, inspection criteria, test coupons, data summaries, and engineering reports.
• Troubleshoot process issues, support root cause analysis and corrective action, and improve yield, repeatability, dimensional accuracy, cleanliness, cycle time, and customer deliverable readiness.
• Collaborate with engineering, R&D, PCB/substrate manufacturing, mOSAT, cleanroom, quality, procurement, vendors, external manufacturing partners, and customer-facing teams to support build readiness, scale-up, and customer deliverables.
• Maintain safe laboratory, cleanroom, molding, laser, machine, chemical, ESD, and advanced manufacturing practices while communicating technical risks, equipment constraints, material concerns, schedule impacts, and customer-impacting issues in a timely manner.

Minimum Qualifications

• Master’s degree or higher in Mechanical Engineering, Materials Science, Manufacturing Engineering, Electrical Engineering, Semiconductor Engineering, Microelectronics Engineering, Applied Physics, or a directly related technical engineering or physical science discipline.
• 3+ years of hands-on experience in precision microfabrication, precision machining, micro-machining, laser processing, EDM, micro-drilling, molding, casting, polymer processing, semiconductor packaging, PCB/substrate manufacturing, advanced manufacturing, process development, or related technical engineering work.
• 2+ years of hands-on experience with CAD and prototyping; SolidWorks experience preferred.
• 2+ years of experience with one or more of the following: micro-molding, liquid injection molding, compression molding, transfer molding, mold tool design, mold-flow FEA, or related molding process development.
• Experience with design for manufacture for molding of polymers, elastomers, silicones, epoxy molding compounds, or related materials.
• Experience working with silicone and epoxy molding compound.
• Experience developing, optimizing, validating, or troubleshooting manufacturing processes involving small features, tight tolerances, metal processing, advanced materials, substrates, molded parts, packaging structures, or precision components.
• Experience applying engineering judgment to process development, parameter selection, tooling or consumable selection, fixture design, mold design, material selection, process validation, technical troubleshooting, or documentation.
• Experience using or supporting precision equipment such as CNC machines, micro-drilling systems, laser processing systems, EDM systems, molding systems, metrology tools, microscopes, profilometers, CMMs, optical inspection systems, or related tools.
• Experience reading and interpreting engineering drawings, design files, tolerance requirements, material specifications, process documentation, customer requirements, and inspection criteria.
• Basic understanding of dimensional tolerance, GD&T, tolerance stack-up analysis, and design for manufacturability.
• Experience collecting, analyzing, and documenting process data, inspection results, test results, deviations, defects, corrective actions, and technical findings.
• Strong technical writing skills, including the ability to prepare process notes, equipment recipes, setup sheets, SOPs, engineering reports, data summaries, and customer-facing technical documentation.
• Ability to support customer product deliverables with accuracy, schedule awareness, documentation discipline, technical judgment, specification alignment, and timely escalation of risks.
• Ability to work effectively in a fast-paced, dynamic, hands-on engineering and advanced manufacturing environment.
• Ability to work on-site in a hands-on engineering, advanced manufacturing, laboratory, cleanroom, prototype manufacturing, and advanced electronics environment.

Required Skills and Knowledge

• Precision microfabrication and micro-hole formation
• Molding, casting, and micro-molding process development
• Compression molding, transfer molding, and liquid injection molding
• Mold tool design, mold-flow FEA, and CFD-supported mold case design
• Silicone, epoxy molding compound, polymers, and elastomer processing
• CAD, SolidWorks, prototyping, and fixture design
• Design for manufacturability for polymers, elastomers, molded parts, and microfabricated components
• Dimensional tolerance, GD&T, and tolerance stack-up awareness
• Laser drilling, EDM, CNC, or micro-machining process awareness
• Metal processing and advanced materials behavior
• Semiconductor packaging and PCB/substrate manufacturing awareness
• Process-window development and parameter optimization
• Tooling, electrodes, optics, nozzles, molds, fixtures, workholding, and consumables
• Micron-scale inspection, analytical testing, and metrology methods
• DOE, SPC, Six Sigma, process capability, and yield improvement
• Root cause analysis and corrective action
• Technical documentation and engineering reporting
• Customer specification review and deliverable support
• Process travelers, SOPs, setup sheets, equipment recipes, and inspection criteria
• Equipment readiness, vendor coordination, and preventive maintenance awareness
• Cross-functional engineering collaboration
• Laboratory, cleanroom, ESD, laser safety, machine safety, chemical safety, and documentation discipline
• Schedule awareness, technical accuracy, and quality accountability

Job Type: Full-time

Benefits:

• Dental insurance
• Health insurance
• Life insurance
• Paid time off
• Relocation assistance
• Vision insurance
• Health Savings Account
• Employee Assistance Program

Education:

• Master's (Required)

Experience:

• hand-on CAD, Solidworks, and prototyping: 2 years (Required)
• micromolding, injection, compression, transfer molding: 2 years (Required)
• mold tool design: 2 years (Required)
• mold flow FEA: 2 years (Required)
• liquid injection, compression, transfer molding: 2 years (Required)

Work Location: In person