Sr Staff Mechanical Design Engineer - Livermore, CA, United States
$163,400 - $214,410 USD yearly
Originally posted 13 May 2026 by the employer.
About the role
The Sr Staff Mechanical Design Engineer defines, develops, and delivers mechanical design solutions for probe card products and systems.
What you'll do
- Lead probe card mechanical design and architecture development, defining system-level strategies and design approaches. - Specify and perform mechanical analyses, including structural, thermal, and tolerance studies. - Define and drive probe characterization and reliability testing, coordinating data review, root-cause analysis, and failure investigations. - Specify, develop, and modify engineering layouts, schematics, detailed drawings, and technical specifications. - Collaborate with manufacturing to build prototypes, alpha, and beta probe cards while supporting design-for-manufacturing and design-for-assembly initiatives. - Interface with internal stakeholders and external customers on engineering issues to meet technical commitments.
What you'll need
- Bachelor's degree with a minimum of 12 years of related experience, a Master's degree with 8 years, or a PhD with 5 years of experience (or equivalent experience). - Demonstrated experience in mechanical design, precision engineering, and precision machine design. - Hands-on expertise with 3D modeling using SolidWorks and Autodesk AutoCAD. - Proficiency in finite element analysis using FEA software, thermal design, and error budgets. - Strong knowledge of Geometric Dimensioning and Tolerancing (GD&T). - Experience with data analysis and programming using MATLAB or Python.
This role has been open 163 days — well above the 51-day median for Hardware Systems Engineering roles.
Hardware Systems Engineering · AI ML Hardware
|
Open roles in category
1017
|
Median days open
51 d
|
Median salary
$154k
|
See the full market breakdown ▾Category comparison, and who else is hiring
| Metric | FormFactor | All employers we track in this specialty (1017 roles · 102 employers) |
|---|---|---|
| Open roles in this specialty | 9 | 1017 |
| Open roles in the wider Software, Firmware & Systems family | 17 | 6277 · 144 employers |
| Median days open | 51 d | 51 d (same as this employer) |
| Median salary (USD postings) | — | $154k |
Who's hiring in this category
- Intel Corporation · 75 open roles · median 36 d
- KLA Corporation · 63 open roles · median 50 d
- Teradyne · 61 open roles · median 36 d
- NVIDIA · 51 open roles · median 68 d
- Applied Materials · 48 open roles · median 67 d
- AMD · 43 open roles · median 53 d
How we counted: 1017 open Hardware Systems Engineering (AI ML Hardware) roles from 102 employers tracked in the SemiconductorJobs index, counted 24 Oct 2026. Specialty figures count only roles carrying this exact specialty label, so an employer's related work in neighbouring specialties is not included there — it is counted in the wider Software, Firmware & Systems family row. Figures refresh nightly.