Karan Rajagopal

Mechanical Design Engineer with 8 years of experience in semiconductor process equipment, specializing in EFEMs, wet etch, cleaning, coating, plating, and panel-level advanced packaging tools. Proven expertise in P&ID-driven electromechanical integration, hands-on tool build, and process plumbing (swaging, hot & cold flaring, pillar connections), with strong application of DFM/DFA principles to deliver SEMI S2/S8-compliant, serviceable, and cleanroom-compatible systems across the full product lifecycle—from concept and detailed design to manufacturing, tool build, and service support. Results driven engineering professional with strong problem-solving, analytical thinking, attention to detail, and cross-functional collaboration skills, capable of leading projects in fast-paced semiconductor manufacturing environments.

Mechanical Engineer II - Yield Engineering Systems (YES) - Coimbatore

(2022-05)

• Product Owner leading cross-functional teams in the design and manufacturing of wafer & glass panel handling equipment for semiconductor front-end and advanced packaging applications.
• Designed and developed EFEM systems with 2, 3, and 4 load-port configurations for glass panels (510 × 515 mm) and wafers (Ø150/200/300 mm), achieving ~30% cost reduction through optimized use of aluminium extrusions.
• Developing an Edge Bead Removal (EBR) tool for PI/PR-coated glass panels, achieving uniform edge quality, consistent coating thickness, and high process repeatability for panel-level advanced packaging.
• Designed and developed a large-footprint ENEPIG plating tool for panel-level semiconductor packaging, covering structural design, chemical module layout, and full P&ID-driven system integration.
• Contributed to the development of a Through-Glass Via (TGV) etch tool, enabling uniform panel edge definition and reliable interconnect formation for advanced packaging applications.
• Developed wet process modules (cleaning, coating, etching) for single-wafer and batch processing, ensuring SEMI-compliant performance and process consistency.
• Led P&ID-driven electromechanical integration, process plumbing, and tool build activities, including high-purity piping (PFA/PVC/PVDF), swaging, hot/cold flaring, and pillar connections. Managed technicians and coordinated cross-functional teams to ensure accurate installation, leak-free chemical delivery systems, on-time tool assembly, and compliance with engineering specifications.
• Executed full product lifecycle development, from concept and prototyping to manufacturing, build, and service support, ensuring robust and scalable system design.
• Designed chemically compatible plastic modules using AWS 2.4-compliant welding techniques, aligned with process requirements.
• Developed detailed 3D models and engineering drawings in SolidWorks, created BOMs using ERP systems, and managed ECO processes to maintain design traceability and configuration control.
• Ensured SEMI S2/S8 compliance and ergonomic design, applied DFM/DFA principles, and collaborated closely with customers on new product development.

Mechanical Engineer I - Swiss Ranks - Coimbatore

(2020-03 - 2022-04)

• Designed a unique adjustable-frame EFEM that allows docking of two or more packaging process modules, improving tool flexibility and scalability.
• Worked on the development of spin coating and spray coating machines using ultrasonic spray nozzles, ensuring uniform coating thickness and process repeatability.
• Designed a powered mobile cart for semiconductor process chambers, enabling real-time monitoring, tracking, and safe movement inside the fab, resulting in improved operational efficiency (Project of the Year – 2021).
• Developed autonomous robotic systems for industrial and public infrastructure applications, including an Autonomous Maneuvering Robot (AMR) for industrial automation and an automated floor sanitizing and cleaning robot for railway applications during the COVID-19 pandemic, with focus on mechanical design, mobility systems, and manufacturability.
• Engaged in all phases of semiconductor process tool development, including concept definition, system architecture, mechanical design, analysis, prototyping, manufacturing, documentation, and service support.
• Produced photo-realistic renderings during the conceptual phase using SolidWorks Visualize to support technical reviews and customer presentations.
• Applied GD&T and drafting standards as per ASME Y14.5-2009 to ensure manufacturing accuracy and quality.

Design Engineer - Shyam Control Devices - Coimbatore

(2018-06 - 2020-02)

• Prepared detailed part and assembly designs for air compressor components using SolidWorks, ensuring compliance with functional and manufacturing requirements.
• Worked as a Design Engineer supporting the manufacture of aeronautical structural components and textile machinery parts, including jigs and fixtures, 3D modelling, and detailed drawings.
• Designed complex vacuum fixtures and multi-setup fixtures for 3-axis and 4-axis CNC milling machines, capable of clamping large aerospace components on large-bed CNC machines.
• Generated CNC programs using Mastercam and actively supported machining operations by troubleshooting machining errors, tooling issues, and process deviations.
• Performed reverse engineering of existing components and assemblies to support upgrades and redesigns.
• Involved in the complete product lifecycle, from initial design evaluation and development through prototyping, validation, and production release.
• Developed Process Flow Diagrams and Process Control Plans, and worked in alignment with SOPs, ECO documentation, and work order requirements.
• Collaborated closely with the Quality team, performing inspections using precision metrology instruments for tight-tolerance components and supporting root cause analysis.
• Created and managed Bills of Materials (BOMs), job route cards, assembly drafts, and MRP-related documentation, while also contributing to plant safety improvement initiatives and manufacturing process documentation.

Bachelor of Engineering - Mechanical Engineering - Sri Shakthi Institute of Engineering & Technology (2014-08 - 2018-05)