Process Engineer, Gold-To-Gold Interconnect & Flip Chip Assembly (Starlink/Akoustis)

Starlink; Bastrop (TX); Presencial; USD 100.000 - 150.000; Jornada completa

Descripción de la vacante

SpaceX, via Akoustis, is seeking a hands-on Process Engineer to develop, optimize, and qualify Gold-to-Gold interconnect and thermosonic flip-chip assembly processes. The role focuses on taking processes from prototype to production while collaborating with equipment, packaging, reliability, and supply-chain partners.

You will drive DOEs, process specs, and qualification reports, while supporting NPI through ramp and addressing failures with advanced analytical methods.

Formación

• Bachelor's degree in an engineering discipline with hands-on semiconductor experience.
• 3+ years in IC assembly, packaging, or advanced packaging environments.
• Experience qualifying new assembly equipment and tooling on the manufacturing floor.

Responsabilidades

• Develop and qualify GGI and thermosonic flip-chip/die-attach processes with DOE-controlled windows.
• Develop gold bumping/interconnect processes and evaluate bond quality and capability.
• Optimize encapsulation, vacuum lamination, and related materials for reliability.
• Support wafer/die handling, cleaning, underfill, reflow, laser marking, and inspection
• Incorporate DFM, perform root-cause analyses, and drive NPI to production release

Conocimientos

GGI bonding

Thermosonic flip-chip

Gold stud bumping

Vacuum lamination

DOE / SPC

Failure analysis

X-ray / SEM

Process capability

Educación

Bachelor's degree in engineering

Herramientas

AutoCAD

ANSYS

COMSOL

Descripción del empleo

SpaceX was founded under the belief that a future where humanity is out exploring the stars is fundamentally more exciting than one where we are not. Today SpaceX is actively developing the technologies to make this possible, with the ultimate goal of enabling human life on Mars.

PROCESS ENGINEER, GOLD-TO-GOLD INTERCONNECT & FLIP-CHIP ASSEMBLY (STARLINK/AKOUSTIS)

Akoustis is now operating as a wholly owned subsidiary of SpaceX providing industry leading RF filters using patented XBAW technology to help drive the mission of making human life multi-planetary, while also connecting the world through Starlink. Our work helps further the impact that Starlink is already making on millions of users around the world, while allowing us to broaden that reach dramatically and continue connecting the unconnected here on earth.

We are looking for a hands-on Process Engineer to develop, optimize, qualify, and implement advanced IC assembly processes, with a focus on Gold-to-Gold Interconnect (GGI) and thermosonic flip-chip bonding. You will take processes from early prototype through production ramp, working directly with equipment and with package engineering, design, manufacturing, reliability, materials, and supply-chain partners.

RESPONSIBILITIES

• Develop and qualify GGI and thermosonic flip-chip / die-attach processes, including bond force, temperature, ultrasonic energy, bond time, alignment, parallelism, and tool selection; establish process windows with DOE to control bond integrity, contact resistance, and mechanical strength
• Develop gold stud bump, gold bump, and gold-to-gold interconnect processes and evaluate bond quality and process capability
• Develop and optimize vacuum mold lamination and related encapsulation (material selection, vacuum, temperature, pressure, time, and cure); troubleshoot voiding, delamination, die shift, warpage, incomplete fill, and bleed
• Support related assembly steps as needed: wafer/die handling, placement, plasma/surface cleaning, underfill, reflow, singulation, laser marking, and inspection
• Select and characterize assembly materials (adhesives, mold compounds, substrates, interconnect materials) for impact on bond strength, adhesion, thermal performance, warpage, and reliability
• Specify, evaluate, install, and qualify assembly equipment (flip-chip bonders, thermosonic bonders, vacuum laminators, plasma, and inspection tools) with suppliers
• Run DOEs, capability studies, and SPC on critical parameters; write process specs, work instructions, control plans, FMEAs, and qualification reports
• Drive NPI from prototype through qualification and production release; perform root-cause analysis and support failure analysis (X-ray, SAM, optical, cross-section, SEM)
• Correlate process settings to electrical, mechanical, and reliability results; apply DFM and own schedules, risks, and production readiness for assigned technologies

BASIC QUALIFICATIONS

• Bachelor's degree in chemical engineering, materials science, mechanical engineering, or other engineering discipline
• 2+ years of hands-on semiconductor assembly, IC packaging, or electronics manufacturing experience (Internship or extracurricular experience is applicable)

PREFERRED SKILLS AND EXPERIENCE

• 3+ years of hands-on IC assembly or advanced packaging experience, including direct GGI or similar gold-based interconnect work
• Hands-on thermosonic flip-chip bonding (force, temperature, ultrasonic power, time, alignment, tooling) and gold stud bumping, gold bumps, or gold-to-gold interfaces
• Vacuum mold lamination or advanced encapsulation with mold sheets, thermally conductive or epoxy molding compounds, or underfills
• Understanding of plasma/surface preparation, organic/ceramic/leadframe/wafer-level substrates, warpage, CTE mismatch, thermal-mechanical stress, adhesion, and delamination
• DOE, SPC, Cp/Cpk, root-cause analysis, FMEA, Six Sigma, and control plans
• Inspection and metrology (X-ray, SAM, optical microscopy, profilometry, cross-section) and interconnect characterization (contact resistance, shear/pull, bond integrity)
• Package reliability testing and standards (JEDEC, IPC), plus experience supporting OSATs or contract manufacturers through development, qualification, and ramp
• CAD (AutoCAD) and familiarity with simulation tools (ANSYS, COMSOL, or similar) is a plus; data analysis with JMP, Minitab, MATLAB, or Python is a plus
• Experience qualifying new assembly equipment and tooling and troubleshooting issues directly on the manufacturing floor

ADDITIONAL REQUIREMENTS

• Onsite in Bastrop, TX (not remote or hybrid)
• Up to 20% domestic and international travel for supplier and manufacturing support
• Willingness to work extended hours or weekends to support key milestones
• Ability to work in a semiconductor manufacturing environment, follow safety and cleanroom requirements, and perform light physical tasks (including lifting up to 25 lbs and handling wafers, substrates, packages, tooling, and assembly samples)
• Strong written and verbal communication skills with engineering, manufacturing, suppliers, and management

ITAR REQUIREMENTS

• To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. Learn more about the ITAR here.

SpaceX is an Equal Opportunity Employer; employment with SpaceX is governed on the basis of merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.

Applicants wishing to view a copy of SpaceX’s [e-mail].