DFM R&D Engineer — Advanced Simulation & Materials
Apple
Cupertino, CA, USA
USD 172,100-305,600 / year + Equity
Posted on May 6, 2026
At Apple, innovative ideas become extraordinary products through deep engineering rigor and strong cross-functional collaboration. The DFM R&D Lab plays a critical role in developing the materials, processes, and predictive modeling frameworks that enable advanced semiconductor packaging and microelectronics technologies to scale reliably to high-volume manufacturing. We are seeking an R&D Engineer who is excited to solve complex mechanical challenges, connect simulation with real-world data, and influence product decisions through thoughtful, physics-based analysis.
This position blends finite element simulation with hands-on materials characterization. You will work on semiconductor packages, PCB systems, and SMT assemblies — developing predictive models that inform design direction, reliability strategy, and manufacturing readiness. You’ll partner closely with design, reliability, and manufacturing teams to define key load cases, build and validate material models, and reduce risk early in development. Your work will help close the gap between simulation and hardware through disciplined experimentation and correlation.
- Develop and execute finite element models (implicit and explicit) for semiconductor packaging, PCB structures, and SMT assemblies
- Analyze thermo-mechanical behavior including warpage, stress evolution, drop/shock, fatigue, and fracture
- Lead or support material characterization efforts (mechanical, physical, chemical) for microelectronics materials
- Build, calibrate, and validate material models using experimental data
- Design and execute DOEs to correlate simulation with test results and support reliability projections
- Drive early design optimization and support root cause investigations of mechanical failures
- Integrate module-level simulations into larger product assembly models
- Communicate analysis results clearly to cross-functional stakeholders
- 7+ years of experience in finite element modeling
- Strong foundation in solid mechanics and thermomechanics
- Experience with CAE tools such as Ansys, Abaqus, or equivalent
- Experience working with materials used in microelectronics applications
- MS or PhD in Mechanical Engineering, Materials Science, Applied Mechanics, Chemical Engineering, or related field
- Experience in warpage, fracture mechanics, fatigue, or drop/impact modeling
- Familiarity with semiconductor packaging and SMT processes
- Experience correlating simulation models with physical testing
- Understanding of DOE methodology and reliability physics
- Strong written and verbal communication skills
- Comfortable working in a fast-paced, cross-functional environment