Resume

MOHAMED E. SAAD, Ph.D.

Milpitas, CA, USA, 95035 -- Phone: (408) 643-9131 -- MohamedSaadE@gmail.com

https://www.linkedin.com/in/mohamed-e-saad-phd-54637337/

--- US Citizen ---

SENIOR OPTO-MECHANICAL DESIGN ENGINEER

· MECHANICAL DESIGN

· OPTO-MECHANICAL DESIGN

· METROLOGY

· STATISTICAL QUALITY CONTROL

Professional optomechanical design engineer offering over fifteen 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      opto-mechanical designs of VCSEL measurement systems at Lumentum
• 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. 
• My      achievements with Ultratech includes an invention patent (under      processing) for a high efficiency cooling method of high power mercury      lamps (2KW).
• My design      work included creating 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.

COMPUTER SKILLS

CAD Packages : Soildworks®,ProE/Creo®,and Siemens NX®

Programming  : MATLAB®

CMMSoftware : PcDmis® GeoPack® and MCosomos®

Image Processing  : IMAQ Vision Builder 6®

Interfacing tool : LabView®

Statistical QC  : Minitab® and SPSS®

EMPLOYMENT HISTORY

I – Staff Opto-Mechanical Engineer at Lumentum Operations, San Jose, CA (Sept. 2020- Current)

· Developing opto-mechanical designs of VCSEL measurement systems.

II- Mechanical Design Engineer 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.

IV- 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.

V- 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.

VI- 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.

VII - 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. 

VIII- 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.

IX-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.

X-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.

EDUCATION

PhD, Mechanical Engineering

University of North Carolina at Charlotte (UNCC), Charlotte, NC, USA (May 2013)

M.Sc., Mechanical Engineering

Alexandria University, Alexandria, Egypt (Feb. 2007)

B.Sc., Mechanical Engineering

Alexandria University, Alexandria, Egypt (June 2000)

PhD dissertation topic: Plasmonic Nanolithography Machine.

My PhD research project was about building a state of the art Plasmonic Nano-Lithography Machine (PLM). Working under the supervision of Prof. Robert J. Hocken, and working as a team member, I was responsible for the precision design and analysis of the machine parts. Also, I was involved in the machining, assembly and system integration phases.

The project was funded by NSF and was a result of the cooperation between the Center for Precision Metrology (CPM) at UNC Charlotte and the Center for Scalable and Integrated NanoManufacturing(SINAM).

M.Sc. thesis topic: Surface Texture Identification Using Optical Methods.

I have developed a binary Morphological Image Processing (MIP) approach to assess the roughness of engineering surfaces. This approach was analyzed mathematically and examined experimentally on real (shaped) specimens and ideal roughness forms (sinusoidal, circular, inverted circular, and triangular) and the results were found to be valuable. I had determined mathematical models to predict some of the surface roughness assessment parameters based on certain morphological statistics of the image and the incidence angle of light. Also, I used the results obtained experimentally to reconstruct a part of the roughness profile of the inspected surfaces. Also, my M.Sc. preparatory studies included Artificial Neural Networks (ANN) but did not contribute to the final thesis.

LEADERSHIP SKILLS

· Helped in training junior engineers when joining my teams.

· President of the American Society for Precision Engineering Student Chapter at UNC Charlotte (ASPE-UNCC) (http://aspe.uncc.edu/) (Academic years 2010-2011 and 2011-2012).

· Secretary of Technology at Graduate & Professional Student Government of UNC-Charlotte (GPSG) (http://gpsg.uncc.edu/). (Academic year 2010-2011).

· Vice president of the Graduate & Professional Student Government of UNC-Charlotte (GPSG) and the chair of the 12th Annual Graduate Research Fair at UNC Charlotte (http://gpsg.uncc.edu/). (Academic year 2011-2012).

· Web mastering websites of the ASPE-UNCC and GPSG. (Academic years 2010-2011 and 2011-2012).

PROFESSIONAL MEMBERSHIPS

· American Society for Precision Engineering (ASPE)

· American Society of Mechanical Engineers (ASME)

· Semiconductor Equipment and Materials International (SEMI)

REFERENCES

· Available upon request.