Wafer Bond Process Engineer (Corvallis, Oregon)

This job is with HP, an inclusive employer and a member of myGwork – the largest global platform for the LGBTQ+ business community. Please do not contact the recruiter directly.Wafer Bond Process Engineer

Description -

HP is seeking a highly motivated Process Engineer to provide technical leadership for wafer bonding technologies supporting both high-volume manufacturing and next-generation MEMS product development. This role is responsible for sustaining and improving existing wafer bonding processes while leading the development, qualification, and implementation of new bonding technologies, materials, equipment, and manufacturing capabilities.

The successful candidate will serve as the technical owner for wafer bonding processes, partnering closely with Operations, Equipment Engineering, Integration Engineering, Product Engineering, Quality, and external suppliers to drive manufacturing excellence, technology advancement, and operational performance. The role requires strong expertise in wafer bonding processes, process development, project leadership, capital equipment acquisition, and process qualification.

Key Responsibilities

Process Ownership and Manufacturing Support

• Serve as the technical owner for wafer bonding processes supporting MEMS manufacturing.
• Sustain high-volume production processes through monitoring, troubleshooting, and continuous improvement activities.
• Drive process stability, yield improvement, defect reduction, cycle time reduction, and cost optimization.
• Lead root-cause investigations for process excursions and implement corrective and preventive actions.
• Develop and maintain process specifications, operating procedures, work instructions, control plans, and FMEA documentation.

Wafer Bonding Technology Leadership

• Demonstrated expertise in wafer-to-wafer and wafer-to-carrier bonding technologies, including direct, adhesive, anodic, oxide, and ionic bonding methods, supporting MEMS, sensors, photonics, biochips, advanced packaging, and heterogeneous device integration applications.
• Experience in surface preparation and pre-bond cleaning processes including plasma treatments, wet cleans, and dehydration bakes to achieve high bond strength and low defectivity.
• Experience with bond alignment, bond tool operation, thermal cure processes, and post-bond processing.
• Utilize metrology, IR inspection, and analytical techniques to evaluate bond integrity, alignment accuracy, defectivity, and interface quality.
• Troubleshoot bonding-related challenges including voids, delamination, particles, alignment issues, and interface defects.
• Drive process characterization, optimization, and margin studies using SPC, DOE, capability analysis, yield analytics, and statistical methodologies.

Process Development and Technology Introduction

• Lead development of new bonding processes from concept through manufacturing implementation.
• Define process windows, characterize critical process parameters, and establish robust manufacturing controls.
• Design and execute DOE studies, capability analyses, and process characterization plans.
• Evaluate emerging materials, equipment technologies, and manufacturing approaches to support future technology roadmaps.
• Support New Product Introduction (NPI), technology transfers, and scale-up activities from development to production.

Project Leadership

• Lead cross-functional projects involving process improvements, technology development, equipment implementation, and manufacturing capacity expansion.
• Develop project plans, schedules, risk assessments, resource requirements, and milestone tracking.
• Coordinate efforts across Manufacturing, Quality, Equipment Engineering, Integration Engineering, Purchasing, Supply Chain, and external partners.
• Communicate project status, risks, mitigation plans, and technical recommendations to leadership and stakeholders.
• Drive execution of strategic initiatives that improve manufacturing capability, product quality, cost, and operational performance.

Capital Equipment Acquisition and Qualification

• Define technical requirements and specifications for new manufacturing equipment and process capabilities.
• Lead capital equipment projects including vendor evaluations, technical assessments, business justification development, factory acceptance testing, source inspections, installation, and production release.
• Partner with suppliers and internal stakeholders to ensure successful deployment of new tools and technologies.
• Establish equipment acceptance criteria, qualification plans, and performance metrics.
• Support capacity planning and long-term manufacturing capability development initiatives.

Process Qualification and Validation

• Lead qualification of new processes, materials, equipment, and process changes.
• Develop qualification strategies, protocols, and reports to ensure manufacturing readiness and process robustness.
• Utilize statistical methods, gauge capability studies, SPC, and risk-based methodologies to support validation efforts.
• Execute process capability assessments and manufacturing readiness reviews.
• Drive implementation of validated solutions into production while ensuring compliance with quality system requirements.

Required Qualifications

• Bachelor's degree in Chemical Engineering, Materials Science, Mechanical Engineering, Electrical Engineering, Physics, or related engineering discipline.
• 5+ years of semiconductor, MEMS, advanced packaging, photonics, sensor manufacturing, or related process engineering experience.
• Demonstrated experience with wafer bonding technologies in manufacturing and/or development environments.
• Strong understanding of process control methodologies including SPC, DOE, process capability analysis, statistical data analysis, and process qualification.
• Experience troubleshooting complex manufacturing processes and implementing sustainable solutions.
• Proven track record leading technical projects across cross-functional organizations.
• Experience leading process development efforts from concept through manufacturing deployment.
• Experience supporting capital equipment acquisition, installation, and qualification.
• Strong written, verbal, and presentation communication skills.
• Demonstrated analytical problem-solving and technical leadership capabilities.

Preferred Qualifications

• Advanced degree (M.S. or Ph.D.) in Engineering, Materials Science, Physics, or related discipline.
• Experience with MEMS manufacturing technologies and cleanroom operations.
• Experience supporting sensor, photonics, biochip, advanced packaging, or heterogeneous integration applications.
• Experience leading capital equipment acquisition and implementation projects.
• Experience with process qualification, validation, and manufacturing readiness activities.
• Knowledge of FMEA, Control Plans, risk-based process development, and quality management systems.
• Familiarity with wafer inspection, metrology, failure analysis, and materials characterization techniques.
• Experience engaging with external suppliers and equipment vendors.
• Formal project management experience leading multidisciplinary engineering teams.
• Experience supporting technology development, NPI, and process transfers into production.

Preferred Competencies

• Technical leadership and influence across organizations.
• Strong project and program management skills.
• Ability to lead through ambiguity and drive execution.