Sr Principal Optical Systems Engineer

Forming Our Future together

FormFactor, Inc. (NASDAQ: FORM), is a leading provider of essential test and measurement technologies along the full semiconductor product life cycle — from characterization, modeling, reliability, and design de-bug, to qualification and production test. Semiconductor companies rely upon FormFactor’s products and services to accelerate profitability by optimizing device performance and advancing yield knowledge. The company serves customers through its network of facilities in Asia, Europe, and North America.

Rooted in our core values — Focus on the Customer, Ownership & Accountability, Respectfully & Effectively Communicate, and Motivate & Develop People — we foster an environment where diverse perspectives are not only welcomed but celebrated. Everyone can make an impact here. Whether it's improving products, supporting customers, or positively influencing peers and the community, the contributions of our people matter.

Shift:

The regular hours for this position are day shift.

Job Description:

FormFactor is seeking a Sr Principal Optical Systems Engineer to lead the architecture, design, modeling, integration, characterization, and validation of advanced optical microsystems and photonic test solutions. This senior individual-contributor role owns complex development efforts from concept through production release and applies deep expertise in optics and photonics to resolve multidisciplinary technical challenges.

The successful candidate will provide technical leadership across engineering, manufacturing, quality, software, and commercial teams; translate customer and product needs into system requirements; and establish robust design, simulation, test, and validation methods. This role influences technical roadmaps and engineering practices through expertise and collaboration rather than direct people management.

Key Responsibilities:

Optical System Architecture and Product Development

• Lead development of advanced optical systems, micro-optical components, and photonic test solutions from concept through commercial deployment.
• Translate customer, product, and application requirements into system architectures, performance specifications, interfaces, and verification plans.
• Own system-level optical performance and manufacturability, reliability, cost, schedule, and scalability of optical subsystems. 
• Drive technical decisions for complex programs with significant ambiguity, multidisciplinary dependencies, and business impact.  Collaborate closely with Mechanical and Controls engineering teams to integrate optical components into precision alignment systems.
• Select and characterize subsystem optical components including fiber array units (FAUs) and optical connectors.
• Apply structured design reviews, risk assessment, and requirements traceability throughout the product lifecycle.

Simulation, Modeling, and Analysis

• Develop and validate advanced optical models using wave optics, diffraction, beam propagation, and photonic-device simulation methods.
• Perform tolerance analysis, sensitivity analysis, error budgeting, and performance prediction for complete optical systems.
• Correlate simulation results with laboratory measurements, production data, and field performance.
  

Test, Metrology, and Automation

• Lead development of optical characterization techniques, measurement methods, fixtures, and system-level verification strategies.
• Define automated test and data-acquisition approaches supporting development, manufacturing, and quality assurance.
• Integrate advanced metrology, image processing, and in-line monitoring solutions for process control and performance verification.
• Use statistical analysis and data-driven methods to improve repeatability, capability, yield, and product performance.

Preferred Qualifications & Experiences:

• Degree or PhD in Optical Engineering, Physics, Photonics, Electrical Engineering, or a related technical discipline.
• Relevant industry experience in optical-system development, photonics, semiconductor equipment, or test and measurement. Equivalent combinations of education and experience may be considered.
• Deep expertise in wave optics, optical-system analysis, and photonic devices.
• Demonstrated success leading complex technical projects from concept through implementation or product release.
• Strong experience with optical modeling, simulation, tolerance analysis, and experimental correlation.
• Hands-on experience developing and validating optical test and measurement methodologies.
• Proven ability to independently solve complex, multidisciplinary problems and make sound technical decisions with incomplete information.
• Excellent written, verbal, and presentation skills, including the ability to communicate complex topics to technical and nontechnical stakeholders.
• Experience with silicon photonics, photonic integrated circuits, or wafer-level optical testing.
• Demonstrated experience in optical design and analysis using ANSYS Zemax.
• Knowledge of advanced microfabrication, additive manufacturing, cleanroom, or semiconductor process technologies.
• Experience with precision optical alignment, opto-mechanical systems, packaging, and system integration.
• Programming and automation experience using Python, MATLAB, LabVIEW, or similar tools.
• Familiarity with machine vision, image processing, automated inspection, statistical process control, or design of experiments.

Skills:

Beamforming, Design for Manufacturability (DFM), Design of Experiments (DOE), Error Budgets, MATLAB, Microoptics, National Instruments LabVIEW, Optical Metrology, Optical Systems, Optomechanics, Physical Optics, Precision Alignments, Python (Programming Language), Silicon Photonics, Statistical Process Control (SPC), Technical Leadership, Tolerance Analysis, Water Testing, Wave Propagation, Zemax

Education & Experience:

Minimum of 8 years of related experience with a Bachelor’s degree; or 6 years and a Master’s degree; or a PhD with 3 years experience; or equivalent experience | Required

Pay Range:

$115,800.00 - $151,935.00

Pay Range Explained:

This role in Beaverton, Oregon pays between $115,800.00 and $151,935.00 per year, depending on your experience, skills, and background. Pay may vary in other locations. We offer a full benefits package, including medical, dental, vision, life insurance, disability coverage, a 401(k) with company match, employee stock purchase plan (ESPP), and paid time off. You’ll also be eligible for quarterly profit-sharing bonuses and flexible spending or savings accounts.

Equal Employment Opportunity Statement

FormFactor is an equal opportunity employer. FormFactor complies with all national, state, and local laws that seek to promote equal opportunities for any applicant or employee without regard to age, race, color, gender, gender identity/expression, national origin, sexual orientation, religion, disability, marital status, pregnancy or related condition, military service, or any other legally protected characteristics. These protections apply to all aspects of employment, including but not limited to, recruitment, hiring, training, promotions, and compensation.

For roles that are designated as remote-eligible, employees cannot be located in: AL, AK, AR, DE, GA, HI, IL, IA, LA, ME, MD, MS, MO, NE, NV, NJ, NM, ND, OK, PA, RI, SC, SD, TN, WV, WI, WY. This list is continuously evolving and being updated, please check back with us if the state you live in is on the exclusion list. A role is remote-eligible only when it is listed as "Remote" in the job location.