Sr. Mechanical Design Engineer (PCBA Test Equipment & Automation)
Confirmed on the employer's own hiring board on Nov 6, 2026. First seen by Alion on Nov 3, 2026. Jabil scores B on the Alion truth index.
1. Job Overview
Responsible for the overall mechanical design and development of PCBA functional test equipment, including Functional Circuit Test (FCT), Automated Test Equipment (ATE), burn-in test systems, pneumatic test fixtures, probe testing equipment, semi-automatic and fully automated test stations, and related automation solutions.
The role covers mechanical concept development, structural design, 3D modelling, component selection, engineering drawings, equipment assembly support, commissioning, troubleshooting, and continuous improvement.
The candidate must have a strong understanding of PCBA testing processes, probe compression mechanisms, precision alignment, and high-speed, short-stroke motion systems, with the ability to independently complete mechanical design and development projects.
2. Key Responsibilities
1. Mechanical Design and Concept Development
- Develop complete mechanical design concepts, equipment layouts, operating sequences, and compression mechanisms based on PCBA testing requirements, test procedures, and fixture specifications.
- Ensure designs meet functional, reliability, safety, and production requirements.
2. Core Testing Mechanism Development
Design and develop key testing mechanisms, including:
- Probe compression and pressing mechanisms.
- Quick-opening and quick-closing test fixtures.
- Precision positioning and alignment mechanisms.
- Pneumatic compression systems.
- Clamshell-type and drawer-type test fixtures.
- Electrostatic discharge (ESD)-safe clamping and pressing mechanisms.
3. Engineering Design and Documentation
- Develop 3D models, assembly designs, and 2D engineering drawings.
- Prepare Bills of Materials (BOM), standard component lists, and component specifications.
- Perform component selection, tolerance analysis, and interference checks.
- Prepare manufacturing drawings and define assembly procedures.
4. PCBA Testing Mechanism Design
Apply engineering principles to ensure reliable test fixture performance, including:
- Proper probe compression and working stroke.
- Accurate pressing stroke and travel limitations.
- Uniform distribution of compression forces.
- Prevention of PCB damage, excessive compression, and deformation.
- Accurate PCB positioning and consistent repeatability.
5. Assembly, Commissioning, and Troubleshooting
- Follow up on component fabrication, equipment assembly, pilot runs, and commissioning activities.
- Troubleshoot mechanical issues such as mechanism jamming, insufficient compression, alignment deviation, poor probe contact, fixture deformation, and mechanical interference.
- Implement effective corrective actions to ensure equipment stability and reliability.
6. Equipment Optimisation and Continuous Improvement
- Improve equipment cycle time and testing efficiency.
- Optimise mechanical designs to reduce weight and improve structural stability.
- Enhance equipment reliability, maintainability, and service accessibility.
- Improve fixture flexibility and compatibility for different product configurations.
7. Technical Documentation
Prepare and maintain comprehensive technical documentation, including:
- Mechanical design specifications.
- Equipment assembly Standard Operating Procedures (SOPs).
- Preventive maintenance manuals.
- Troubleshooting and corrective action reports.
- Engineering improvement reports.
3. Job Requirements - Essential Technical Qualifications
1. Educational Background
- Bachelor's degree or above in Mechanical Engineering, Mechanical Design, Mechatronics Engineering, or a related discipline.
2. Relevant Working Experience
- Minimum 5 years of hands-on experience in independent mechanical design and development of PCBA test equipment, test fixtures, ATE, or FCT systems.
- Candidates with strong knowledge of electronic circuit board testing processes will have an advantage.
3. CAD Design Proficiency
Proficient in SolidWorks, including:
- 3D mechanical modelling.
- Assembly modelling and design.
- 2D engineering drawings.
- Interference detection.
- Motion simulation and mechanical validation.
4. Core PCBA Testing Mechanism Design Knowledge
Must demonstrate strong technical expertise in:
- Spring-loaded test probes: Working stroke, preload, compression allowance, and probe contact reliability.
- PCB positioning and protection: Error-proofing (Poka-Yoke), PCB damage prevention, soft rubber cushioning, and mechanical travel limiters.
- Pneumatic compression systems: High-speed, short-stroke pneumatic mechanisms with precise positioning and controlled stopping.
- Thin PCB handling: Anti-deformation design, floating alignment mechanisms, and self-adjusting clamping structures.
5. Mechanical Components and Motion Systems
Familiar with the selection and application of:
- Standard mechanical components.
- Pneumatic cylinders and related components.
- Sensors and detection devices.
- Linear guide rails and ball screws.
- Compact servo motors and stepper motor systems.
- Precision motion control mechanisms.
6. Precision Engineering and Tolerance Control
- Strong understanding of precision component fits and tolerances.
- Knowledge of assembly tolerance stack-up analysis.
- Ability to control fixture positioning accuracy and repeatability.
- Experience in managing probe-to-PCB alignment accuracy.
7. Independent Equipment Design and Risk Assessment
- Capable of independently developing complete mechanical equipment structures and assemblies.
- Able to assess potential mechanical design risks, including:
- Structural interference and component collisions.
- Insufficient or uneven compression force.
- Probe contact failures and alignment deviations.
- PCB damage and fixture deformation.
- Long-term wear, ageing, and mechanical reliability issues.
The successful candidate must demonstrate strong practical engineering knowledge, independent problem-solving capabilities, and the ability to deliver reliable, production-ready PCBA testing equipment and automation solutions.
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