R&D Engineer

Onsite Position Summary

The Client is seeking a Principal R&D Engineer to support the development and transfer of advanced wafer-based manufacturing processes within a highly regulated product development environment. This role will be responsible for developing, optimizing, and scaling innovative fabrication processes from concept through manufacturing transfer while ensuring robust process performance, reliability, and manufacturability.

Essential Responsibilities

• Lead the innovation, development, optimization, and transfer of advanced manufacturing processes into production environments.
• Develop highly stable, scalable, and cost-effective wafer fabrication processes to support product development and commercialization.
• Design, execute, analyze, and document experiments to establish robust process windows and manufacturing controls.
• Develop and support fabrication processes involving: Thin-film and metal deposition technologies, Photolithography and patterning techniques, Polymer and organic layer deposition processes, Surface treatment and microfabrication methods.
• Apply Design for Reliability and data-driven methodologies throughout process development activities.
• Define equipment, tooling, metrology, and manufacturing requirements necessary to support process development and scale-up.
• Establish process controls, monitoring strategies, and manufacturing specifications.
• Perform process characterization, optimization, and root cause investigations to improve yield, reliability, and process capability.
• Utilize statistical methods and scientific principles to design experiments and evaluate process performance.
• Conduct and support: Equipment IQ, Operational IQ, Performance IQ, Test Method Validations (TMV), Measurement System and Gage R&R studies.
• Collaborate with Product Development teams to ensure product designs align with manufacturing capabilities and process requirements.
• Provide technical support for manufacturing operations and resolve complex process or equipment-related challenges.
• Evaluate and integrate new materials, technologies, equipment, and manufacturing concepts.
• Generate and maintain technical reports, protocols, engineering documentation, and quality records.
• Ensure compliance with applicable quality systems, regulatory requirements, and internal procedures.
• Mentor and provide technical leadership to engineers and cross-functional project teams.

Education Required Qualifications

• Bachelor's Degree in Engineering or related technical discipline required.
• Minimum of 7 years of relevant engineering experience with a Bachelor's degree, or
• Minimum of 5 years of relevant engineering experience with an advanced degree.

Required Technical Skills

• Thin Film / Metal Deposition Processes
• Photolithography and Patterning Techniques
• Design of Experiments (DOE) and Process Development

Preferred Qualifications

• Advanced degree in: Materials Science, Mechanical Engineering, Chemical Engineering, Chemistry, Physics, Biomedical Engineering, or Related Technical Discipline
• Experience with microfabrication or MEMS technologies
• Experience with: Photolithography, Thin-film deposition, Patterning and etching techniques, Semiconductor manufacturing processes
• Experience developing processes from concept through manufacturing transfer
• Experience supporting high-volume manufacturing environments
• Knowledge of automated equipment, machine vision systems, and automated metrology tools
• Experience programming, troubleshooting, or supporting automated manufacturing systems
• Experience with: Design for Reliability (DfR), Design for Six Sigma (DFSS), Lean Manufacturing, Six Sigma methodologies, Lean Six Sigma Green Belt or Black Belt certification preferred
• Knowledge of statistical analysis software such as: JMP, Minitab, Similar analytical tools