Dr. Mohamed Saad Expert Mechanical and Optomechanical Design Engineer.
From start to finish, we help get the job done!
Dr. Mohamed Saad Expert Mechanical and Optomechanical Design Engineer.
From start to finish, we help get the job done!
We Build Precision Engineering Systems
Our Services
- MECHANICAL DESIGN
- OPTO-MECHANICAL DESIGN
- METROLOGY
- STATISTICAL QUALITY CONTROL
About me
Professional optomechanical design engineer offering over ten years experience in design of mechanical and optomechanical systems used in capital semiconductor equipment and precision engineering.
Deep understanding and hands on experience applying GD&T standards, Gauge R&R, DoE, dimensional and geometrical metrology.
Over ten years experience in creating CAD models, assemblies, FEA, CFD, and blue prints. Also, I strictly follow DFM, DFA, and DFX guidelines. I offer an extensive experience in designing high precision machines and fluency in using CAD packages such as Solidworks® , Siemens NX®, and ProE®.
Excellent team player with high organizational and multitasking skills.
HIGHLIGHTS OF CAREER ACHIEVEMENTS
- Developing UHV system at KLA.
- Developing mechanical designs of assemblies for the new synchrotron at Lawrence Berkeley National Laboratory (LBNL).
- Opto-mechanical design of key assemblies to be used in the new KLA’s mask inspection capital equipment.
- Improved the design of mechanical and opto-mechanical assemblies in the next generation lithography system in Ultratech-Veeco.
- Developed high efficiency cooling method of high power mercury lamps (2KW) at Ultratech (Veeco)
- CAD models, assemblies, GD&T , 2D drawings, FEA analysis, CFD analysis and bolt calculations.
- Introduced, designed, and applied a state-of-the-art metrology method and tools to align mechanical and optomechanical subsystems inside the lithography machine at Ultratech-Veeco. These tools (to be patent soon) also confirm the right distances and relative positions between many optical components.
- Designed a fiber connection module and improved the design of an opto-mechanical module used in the next generation leveling sensor in ASML lithography machine (TWINSCAN™).
- Designed fixtures necessary for vibration analysis and shock testing of optomechanical modules to be used in next generation ASML TWINSCAN™.
- Designed, assembled and tested Wafer Transfer Stage which is a critical module in KLA-Tencor SURFSCAN™ new generation.
- Designed, assembled and tested Plasmonic Nanolithography Machine.
- Developed optical measuring system to measure the Coefficient of Thermal Expansion of ball bar (used for calibration CMMs).
- Developed a binary Morphological Image Processing (MIP) approach to assess surface texture of engineering surfaces.
- Developed an image stitching method to measure surface profile of large hemisphere using WLI.
- Developed a Starter Bibliography for Surface Metrology presented at ASME B46.
- Teaching undergraduate mechanical engineering students for 10 years.
EMPLOYMENT HISTORY
I- Staff Mechanical Design Engineer at Lumentum Operations- San Jose, CA (September 2020- Current)
· Developing VCSEL inspection systems.
II – Mechanical Design Engineer - Project- at Lawrence Berkeley National Laboratory (LBNL)- Berkeley, CA (June 2020- August 2020)
· Designing mechanical assemblies of the new generation synchrotron at LBNL.
III - Opto-mechanical Design Engineer at KLA- Milpitas, CA (July 2019- May 2020)
· Designing opto-mechanical assemblies to mount optical elements such as mirrors and lenses. These assemblies will be used in the KLA’s new mask inspection tool (UHV system).
· Developing vibration isolation system of the tool to achieve nano-scale positioning tolerances.
· Developing alignment tools for aligning the optical system after tool assembly.
· Developing 6DoF adjustment capabilities in key assemblies.
III- Senior Opto-mechanical Design Engineer at Veeco- San Jose, CA (April 2018- June 2019)
· Designing the mechanical mount for high power mercury lamp (2KW), The design provides means to adjust the lamp spark with respect to the ellipsoid focal point (tip-tilt and XYZ),
· The design included an extensive use of Solidworks® to create the CAD models, assemblies, and 2D drawings. Also Computational Fluid Dynamics (CFD) was used extensively to determine the required cooling air flowrate and directions to maintain the lamp and ellipsoid temperatures within specification limits,
· Bolt-calculations were conducted using an accurate calculation module,
· Design documents were maintained and shared using SAP system,
· Invented a new cooling method (patent is under processing) that provides high efficiency cooling for high power mercury lamps (2KW),
· Developed a metrology system and tools for aligning optical components and precisely put them in the right relative position. This method to be patent later.
IV- Design Engineer 2 at ASML – Wilton, CT (January 2016- September 2017)
- Designed the fiber connection interface which connects the UV fiber optic cables outside the wafer leveling sensor and the optical modules inside. The wafer leveling sensor is a key module in the next generation ASML TWINSCAN™ ,
- Improved the design of an optical module (Spot Mirror Assembly) which consists of multiple optical and mechanical elements, including an extensive investigation of the best methods to attach glass to metal. This module used in the next generation leveling sensor in ASML lithography machine (TWINSCAN™),
- Designed fixtures necessary for vibration analysis and shock testing of optomechanical modules in order to evaluate the effect of the transportation on the wafer leveling sensor performance,
- Worked with all cross-functional teams through ASML product development cycle to achieve the best design quality, My work included an extensive use of the Siemens NX®,
- Followed ASML way-of-working and documentation protocols.
V- Metrology Engineer at Mitutoyo America Corp., Aurora, IL. (March 2015 – Dec. 2015)
- Conducted Gage R&R studies on metrology systems,
- Applied standard methods to calibrate standard artifacts such as ball bars, reference balls, reference spheres, optical gratings and customized references.
- Developed measuring methods and CMM codes required to measure commercial products and challenging artifacts.
VI - Mechanical Design Engineer at KLA-Tencor, Milpitas, CA. (March 2013- March 2015)
- Designed, assembled and tested a state of the art Wafer Transfer Stage which is a critical module in KLA-Tencor’s SURFSCAN™ new generation,
- Investigations included finding a manufacturable material that has a significantly low coefficient of friction when gripping coated silicon wafers,
- Particles generation and immigration were studied extensively as well as the heat generation and dissipation,
- My work included an extensive use of the Solidworks® and ProE®.
- The design includes dynamic and static analysis, Computational Fluid Dynamic (CFD) analysis, and Finite Element Analysis (FEA). Also I shared in the FMEA and reliability studies.
- Worked as a team member following KLA-Tencor Product Life Cycle standards.
VII- Teaching and Research Assistant, Department of Mechanical Engineering and Engineering Science, UNCC, Charlotte, NC, USA (Sept. 2007 – Jan 2013)
- Worked on three projects under the supervision of Prof. Robert J. Hocken, The first project was about the determination of the Coefficient of Thermal Expansion of Ball Bars that can be used in the CMM calibration.
- The second project was about image stitching of WLI images taken on a large diameter semi-sphere. The third project (my PhD dissertation topic) was about building a maskless plasmonic nanolithography machine.
· Worked for an academic year with Prof. Jay Raja, during which I made a preliminary data base that can be used to facilitate surface texture assessment of engineering surfaces.
VIII-Summer internship in Ford Motor Company – Livonia- Michigan (May – August 2008)
· Worked on three different metrological projects related to surface roughness and flatness measurement of motor parts. Also, I was validating a software used for roughness measurement.
IX-Teaching Assistant, Faculty of Engineering, Alexandria University, Alexandria, Egypt (Sept. 2000 – Aug. 2007)
I have taught the following courses:
- Computer Aided Inspection (CAI)
- CAD\CAM.
- Dimensional Metrology.
- Geometrical Metrology.
- Three Dimensional Metrology.
- Laser Based Measuring Systems.
- Co-ordinate Measuring Metrology (CMM).
- Statistical Process Control (SPC).
- Statistical Quality Control (SQC).
- Quality Assurance (QA).
- Quality Engineering (QE).
- Total Quality Management (TQM).
- Design of Mechanical Elements.
- Machining Processes.
- Metal Forming Processes.
- Failure Analysis.
- Statistical Analysis and Design of Experiments.
- Operations Research.
- Engineering Economy.
- Production and Operations Management.
· Participated in supervising graduation projects concerning dimensional and geometrical metrology, quality improvement, and total quality management. My role was to help students in carrying out the experiments of the practical part of their projects.
· Taught courses to engineers and technicians in the industrial field under the supervision of American University in Cairo (AUC) and Arab Academy for Science and Technology and Maritime Transport (AAST) These courses include "Fits and Tolerances" for technicians in Alexandria Iron and Steel Company, "Statistics" for engineers in Alexandria Iron and Steel Company, “Quality Engineering" for engineers in Petroleum Maritime Service Co.(PMS),"ISO 9000-2000 Series" for managers in the Egyptian Imports and Exports Monitoring Organization.