Staff Mechanical Engineer
Job Summary & Responsibilities
Apply the Onto Innovation product development process from concept through manufacturing release, with strong emphasis on control system architecture, integration, and validation for precision semiconductor capital equipment.
Lead mechanical and mechatronic design with a focus on dynamics-informed design to enable high-performance motion control (stiffness, damping, eigenfrequency management, thermal stability).
Develop and support motion control systems including:
- Servo loop design, tuning, and optimization (PID, feedforward, notch filtering)
- Stage control architectures (single-axis, multi-axis, coordinated motion)
- Integration of encoders, interferometers, and high-resolution feedback systems
Perform dynamic system analysis including:
- Modal analysis and frequency response (Bode/Nyquist)
- Vibration characterization and mitigation aligned to VC standards
- Identification and mitigation of structural resonances impacting control bandwidth and stability
Conduct controls-driven design analysis, including:
- Tolerance stack-up with impact on control performance (following error, settling time)
- FEA with focus on dynamic behavior (mode shapes, compliance paths)
- Thermal-mechanical interactions affecting control accuracy and drift
Define and validate control performance requirements, including:
- Positioning accuracy, repeatability, settling time, and throughput
- Stability margins and robustness to disturbances
- System-level error budgeting (mechanical + control contributions)
Participate in system integration and commissioning, including:
- Servo tuning and optimization on hardware
- Prototype bring-up, system identification, and parameter extraction
- Debugging control instabilities, noise, and cross-axis coupling
Support system-level characterization and validation:
- Frequency response measurement (FRF), step response, tracking performance
- Vibration sensitivity and environmental coupling
- Compliance with SEMI and other performance standards
Collaborate cross-functionally with controls, electrical, and software teams to:
- Define control architectures and interfaces
- Translate system requirements into control specifications
- Ensure alignment between mechanical design and control performance
- Support multiple programs by delivering controls-aware designs that meet schedule, cost, and performance targets
Provide technical support to manufacturing, service, and customers for motion performance issues, root cause analysis, and field improvements.
Qualifications
- Controls-Relevant Qualifications
- BS/MS/PhD in Mechanical Engineering or related field with strong emphasis on dynamics, controls, or mechatronics
- 7+ years of experience in precision mechanical/mechatronic systems with hands-on motion control and servo tuning experience
- Strong fundamentals in:
- Control systems engineering (feedback control, stability, loop shaping)
- Structural dynamics and vibration analysis
- System identification and frequency-domain analysis
- Experience with:
- Servo tuning tools and motion controllers
- Multi-axis stage systems and precision motion platforms
- Sensors and feedback systems (encoders, interferometers, capacitive sensors)
- Proficiency in:
- FEA tools for dynamic and thermal modeling
- Troubleshooting complex system-level performance issues
- Familiarity with semiconductor equipment or similar high-precision, high-bandwidth motion systems
- Understanding of compliance standards (SEMI, CE, UL) with respect to system performance and safety
- Strong ability to:
- Diagnose and resolve control-performance limitations (mechanical vs control root cause)
- Work at system level across mechanical, electrical, and software domains
- Communicate complex control concepts clearly to cross-functional teams
- Must be able to travel internationally to customer sites at least 20% of the time, with additional travel as business needs require.