Senior/Staff Process Engineer (Flip Chip)
LumilensJob Title
Senior/Staff Process Engineer (Flip Chip)
Role Summary
Lead process development and technical support for flip chip assembly of silicon photonic wafers, working with OSATs or internal assembly lines. Focus on process integration, yield improvement, materials qualification, and reliability validation to enable robust, manufacturable production.
Experience Level
Senior-level. Guidance: typically requires 5+ years of hands-on industry experience in flip chip assembly.
Responsibilities
Own end-to-end flip chip process development, qualification, and failure resolution to support NPI and volume production.
- Develop and support flip chip processes (plasma cleaning, flux engineering, pick & place, reflow, underfill, curing, TCB/NCP flux-less flows).
- Design and execute DOE to define process windows, margins, and integration with upstream processes (e.g., bump/FO) to improve yield and manufacturability.
- Evaluate and qualify manufacturing materials (NCP, flux, underfill, adhesives) and manage incoming material quality control.
- Plan and lead reliability validations (TCT, HAST, HTS) and thermal/mechanical stress characterization.
- Perform root-cause failure analysis for flip-chip-specific defects (flux voids, residues, misalignment, die warpage, underfill voids) and implement corrective actions.
- Establish and monitor SPC control plans; track process variation to ensure long-term stability.
- Prepare SOPs, work instructions, process failure reports, and engineering change documents; support NPI and process verification.
Requirements
Key technical and practical skills required to perform the role.
- 5+ years of hands-on industry experience in flip chip assembly and process development.
- Deep practical experience with plasma cleaning, flux engineering, pick & place, reflow, underfill, curing, and/or TCB/NCP flux-less flows.
- Experience designing and analyzing DOE for process characterization and margin expansion.
- Competence in finite element simulation concepts related to warpage, thermal dissipation, and mechanical integrity.
- Established experience with industry validation and quality tools: FMEA, SPC, and structured 8D problem solving.
- Material selection and qualification experience for assembly materials and incoming material quality control.
- Proficiency with statistical/analytical tools such as JMP or Minitab.
Education Requirements
Bachelor's or Master's degree in Materials Science, Chemical Engineering, Mechanical Engineering, Microelectronics, or an equivalent technical discipline.
About the Company
Company: Lumilens
Headquarters: San Jose, CA, USA
Lumilens develops integrated photonics and optical interconnect solutions for high-speed data communication and chip-to-chip interfaces, focusing on optical front-end hardware and co-packaged optics for advanced semiconductor systems.
