Microfabrication & Molding Process Engineer

Job Description

Microfabrication & Molding - Process Engineer Responsibilities

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• 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.
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• 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.
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• 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.
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• Operate and improve compression molding, transfer molding, liquid injection molding, micro-molding, casting, and related polymer or elastomer processing systems.
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• 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.
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• Plan and execute DOE, feasibility trials, parameter studies, process capability studies, prototype builds, analytical testing, metrology, dimensional inspection, microscopy, and related characterization activities.
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• Create and maintain process documentation, including equipment recipes, mold setup sheets, process parameters, travelers, SOPs, inspection criteria, test coupons, data summaries, and engineering reports.
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• Troubleshoot process issues, support root cause analysis and corrective action, and improve yield, repeatability, dimensional accuracy, cleanliness, cycle time, and customer deliverable readiness.
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• 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.
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• 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.
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Minimum Qualifications

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• 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.
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• 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.
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• 2+ years of hands-on experience with CAD and prototyping; SolidWorks experience preferred.
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• 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.
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• Experience with design for manufacture for molding of polymers, elastomers, silicones, epoxy molding compounds, or related materials.
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• Experience working with silicone and epoxy molding compound.
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• 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.
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• 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.
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• 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.
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• Experience reading and interpreting engineering drawings, design files, tolerance requirements, material specifications, process documentation, customer requirements, and inspection criteria.
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• Basic understanding of dimensional tolerance, GD&T, tolerance stack-up analysis, and design for manufacturability.
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• Experience collecting, analyzing, and documenting process data, inspection results, test results, deviations, defects, corrective actions, and technical findings.
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• 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.
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• Ability to support customer product deliverables with accuracy, schedule awareness, documentation discipline, technical judgment, specification alignment, and timely escalation of risks.
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• Ability to work effectively in a fast-paced, dynamic, hands-on engineering and advanced manufacturing environment.
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• Ability to work on-site in a hands-on engineering, advanced manufacturing, laboratory, cleanroom, prototype manufacturing, and advanced electronics environment.
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Required Skills and Knowledge

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

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Benefits:

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

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• Master's (Required)
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Experience:

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