Senior Motion Controls Engineer

Senior Motion Controls Engineer - Boston, MA Area

DESCRIPTION:

As a Senior Motion Controls Engineer, you will lead the development, analysis, and optimization of precision motion systems that enable nanometer-level performance in advanced semiconductor equipment.

You will work at the intersection of controls engineering, dynamics, mechatronics, precision mechanics, and system integration. Your expertise will be instrumental in characterizing machine dynamics, tuning high-performance control systems, optimizing stage performance, and developing calibration methodologies that maximize equipment accuracy and productivity.

The ideal candidate is a hands-on technical expert with deep knowledge of motion control, frequency-domain analysis, system identification, and dynamic behavior of precision equipment.

Key Responsibilities:

• Lead the development, analysis, and optimization of precision motion systems for semiconductor metrology and inspection equipment.
• Characterize machine and stage dynamics through experimental measurements, system identification, and analytical modeling.
• Measure and analyze frequency response functions (FRFs), transfer functions, coherence, disturbance spectra, and closed-loop performance metrics.
• Develop, tune, and optimize motion control strategies, including:
• PID control
• Feedforward control
• Disturbance rejection
• Trajectory optimization
• Perform controller tuning and performance validation to achieve demanding requirements for settling time, tracking accuracy, throughput, and stability.
• Conduct modal testing and modal analysis to identify structural resonances and visualize system dynamic behavior.
• Collaborate with mechanical engineers to improve system performance through optimized structural and dynamic design.
• Develop and implement machine, stage, and sensor calibration methodologies to improve positioning accuracy and measurement performance.
• Support root-cause analysis of machine performance issues related to vibration, servo behavior, structural dynamics, and system integration.
• Use simulation and modeling tools to predict dynamic performance and guide design improvements.
• Collaborate cross-functionally with mechanical, optical, electrical, software, systems, and algorithm teams to develop fully integrated solutions.
• Create technical documentation, test procedures, performance reports, and calibration workflows.
• Provide technical leadership, mentor junior engineers, and contribute to motion control technology roadmaps.

Qualifications Required:

• MSc or PhD in Control Engineering, Mechanical Engineering, Mechatronics, Aerospace Engineering, Applied Physics, Electrical Engineering, or a related field.
• 8+ years of experience developing high-performance motion control systems.
• Strong expertise in: Motion control systems, Servo tuning, Frequency-domain analysis, System identification, Dynamic modeling, Machine calibration
• Hands-on experience measuring and interpreting: Frequency response functions (FRFs), Bode plots, Nyquist plots
• Time-domain and frequency-domain performance metrics
• Experience tuning feedback and feedforward control loops for precision motion systems.
• Strong understanding of system dynamics, vibration, resonance, damping, and disturbance rejection techniques.
• Experience performing modal testing and modal analysis.
• Proficiency with MATLAB/Simulink and engineering analysis tools.
• Experience working in cross-disciplinary engineering teams.
• Demonstrated ability to independently drive technical investigations and deliver results.
• Experience performing structural dynamic simulations and Finite Element Analysis (FEA/FEM) is preferred