Staff Mechanical Design Engineer

Job Title

Staff Mechanical Design Engineer

Role Summary

Join the Advanced Technology Infrastructure team to lead mechanical architecture and detailed design of high-performance semiconductor test infrastructures, including sockets, optical connectors, silicon photonics FAUs, and thermal head assemblies. The role delivers tolerance-aware, manufacturable hardware that supports reliable electrical and thermal validation for high-power XPU and silicon photonics platforms.

Experience Level

Senior (Staff-level). The posting references experience ranges such as Bachelor's + 3–5 years or advanced degree + 2–3 years; equivalent professional experience is accepted.

Responsibilities

Key responsibilities include delivering robust, production-ready mechanical designs and driving cross-functional alignment with thermal, packaging, test, and manufacturing teams.

• Lead CAD development and mechanical design of test sockets, thermal heads, pedestals, handlers, and loading/clamping mechanisms.
• Perform tolerance stack-up analysis and manage bond-line thickness (BLT) and contact stack compliance.
• Design compliant mechanisms (springs, flexures, preload structures) to tolerate manufacturing and alignment variation.
• Architect socket-to-thermal-head integration for precise alignment and repeatable contact under dynamic loads.
• Develop manufacturable fluid-integrated internal geometries (micro-channels, jet-impingement manifolds) with thermal teams.
• Define pedestal planarity, flatness, and uniform pressure mapping to reduce DPPM and reliability risks.
• Select CTE-matched materials and design to minimize warpage across temperature excursions.
• Create modular, scalable CAD architectures and reusable design kits for high-volume deployment.
• Drive Design for Manufacturability (DFM) and partner with manufacturing, reliability, and supply-chain on production readiness.
• Interface with external vendors for precision machining, surface finishing, coatings, and component fabrication.

Requirements

Must-have technical skills and experience, with preferred items listed separately.

• Must-have: Proven mechanical design experience in precision hardware or high-tolerance assemblies.
• Must-have: Demonstrated expertise in tolerance stack-up, compliant mechanisms, and mechanical interface design.
• Must-have: Proficiency with 3D CAD tools (e.g., NX, SolidWorks, Creo) and familiarity with drawing standards.
• Must-have: Solid understanding of materials, contact mechanics, and manufacturability constraints.
• Must-have: Ability to translate complex technical requirements into clear mechanical architectures and detailed designs.
• Must-have: Strong communication skills and experience leading technical discussions across disciplines.
• Nice-to-have: Experience with semiconductor test sockets, handlers, thermal head assemblies, and FAU/CPC connector designs.
• Nice-to-have: Familiarity with fluid-based cooling designs and integrating heaters, sensors, and wiring within compact assemblies.
• Nice-to-have: Background in high-volume manufacturing, DPPM-driven quality programs, prototype bring-up, and production ramp support.
• Nice-to-have: Prior leadership on cross-program platform or infrastructure designs and vendor management.

Education Requirements

Bachelor's in Computer Science, Electrical Engineering, or a related field (typical pairing: Bachelor's + 3–5 years); or a Master’s or PhD in Computer Science, Electrical Engineering, or related fields (typical pairing: 2–3 years). The posting also accepts equivalent professional experience in lieu of a formal degree.

About the Company

Company: Marvell Technology

Headquarters: Santa Clara, California, United States

Marvell’s semiconductor solutions serve as essential building blocks of the data infrastructure connecting our world, driving innovation across enterprise, cloud, AI, and carrier architectures. The company focuses on creating transformative technology that shapes the future.