Sr. Staff Thermo-Mechanical Engineer
About Marvell
Marvell’s semiconductor solutions are the essential building blocks of the data infrastructure that connects our world. Across enterprise, cloud and AI, and carrier architectures, our innovative technology is enabling new possibilities. At Marvell, you can affect the arc of individual lives, lift the trajectory of entire industries, and fuel the transformative potential of tomorrow. For those looking to make their mark on purposeful and enduring innovation, above and beyond fleeting trends, Marvell is a place to thrive, learn, and lead.
Your Team, Your Impact
We are seeking a Sr. Staff Thermo Mechanical Engineer to join our Advanced Technology Infrastructure team, focusing on mechanical simulation and structural reliability of semiconductor test and validation infrastructure. This role plays a critical part in ensuring the mechanical robustness, dimensional stability, and long term reliability of sockets, test assemblies, handlers/thermal heads and package level interfaces used in next generation high power XPU and Silicon Photonics programs.
What You Can Expect
Perform advanced thermo-mechanical finite element simulations to evaluate stress, strain, deformation, and structural integrity of test sockets, thermal heads, interconnects, fixtures, handlers, and package interfaces.
Lead warpage and deformation analysis for multi-material assemblies, accounting for CTE mismatch, nonlinear material behavior, temperature gradients, and boundary conditions.
Create thermal cycling and mechanical fatigue models to predict long-term reliability, including creep, stress relaxation, and interface degradation.
Translate package and test infrastructure requirements into mechanical design constraints and reliability metrics for early architecture decisions.
Correlate simulation results with mechanical testing, thermal cycling data, warpage metrology, and strain measurements to validate and refine models.
Identify mechanical risk drivers and recommend design, material, or process changes to improve robustness, manufacturability, and yield.
Support root-cause analysis of lab or field issues related to cracking, delamination, contact degradation, excessive warpage, or mechanical instability.
Develop simulation methodologies, modeling guidelines, and best practices to improve consistency and prediction accuracy across programs.
Partner closely with thermal, packaging, test, reliability, and manufacturing teams to ensure mechanical compatibility and system-level alignment.
Interface with external vendors and manufacturing partners on material selection, tolerances, and mechanical performance expectations.
Document and communicate results through clear technical reports, design reviews, and executive-level summaries.
What We're Looking For
Bachelor’s degree in Computer Science, Electrical Engineering or related fields and 5-10 years of related professional experience or Master’s degree and/or PhD in Computer Science, Electrical Engineering or related fields with 3-5 years of experience or equivalent professional experience in lieu of a formal degree.
Deep experience in thermo-mechanical simulation and structural FEA for complex, multi-material systems.
Strong understanding of solid mechanics, material behavior, heat-induced stress, fatigue, and reliability physics.
Experience modeling warpage, contact mechanics, and mechanical interfaces in semiconductor or high-precision hardware.
Proficiency with simulation tools such as ANSYS, Abaqus, COMSOL, or equivalent, including nonlinear and transient analyses.
Hands-on experience correlating simulation with physical testing and metrology.
Ability to translate complex simulation results into actionable design guidance.
Strong communication skills and ability to influence cross-functional technical decisions.
Experience with semiconductor packaging, test infrastructures, probe cards, or handler-integrated mechanical systems.
Familiarity with thermal cycling standards and hardware qualification methodologies.
Experience with process modeling and manufacturing-induced stress analysis.
Scripting or automation experience using Python, MATLAB, or similar tools.
Prior technical leadership on cross-org infrastructure or platform programs.
Expected Base Pay Range (USD)
$118,010 - $176,800, $ per annum
Additional Compensation and Benefit Elements
Marvell is committed to providing exceptional, comprehensive benefits that support our employees at every stage - from internship to retirement and through life's most important moments. Our offerings are built around four key pillars: financial well-being, family support, mental and physical health, and recognition. Highlights include an employee stock purchase plan with a 2-year look back, family support programs to help balance work and home life, robust mental health resources to prioritize emotional well-being, and a recognition and service awards to celebrate contributions and milestones.