Semiconductor Manufacturing & Optical Metrology
ASML US - Wilton, CT
05/2021 - 2023
Worked on the YieldStar optical metrology platform, including the 375F, 380G, and 1385 systems, for process monitoring and control as well as lithography system stability and matching. Performed sub-system assembly, optical alignment, functional testing, equipment calibration, station setup, and process development support.
The Wilton site is one of ASML's main global manufacturing tech hubs, building wafer alignment sensors and DUV/EUV sub-systems. High-mix, schedule-driven environment; cross-trained across multiple sub-system competencies.
Sensor alignment, UIA alignment, focus branch alignment, Z-stage installation, Pupil Branch, Alignment Branch, Reference Branch, cables and covers. Pre-qualifications and final qualifications.
Measured sensor performance, calibrations, alignment of branch optics, objective lens performance, and diffraction-based overlay measurements.
Build, alignment, and diagnostic execution on production photolithography systems shipped to leading-edge semiconductor fabs. Familiarity with electro-optical, optical-mechanical, and imaging and testing systems.
Owned high-precision sub-assembly qualification under tight contamination, ESD, and tolerance controls comparable to fab module qualification standards.
Standardized tools and electronic equipment for assembly, install, removal, testing, and troubleshooting on optical metrology systems: torque wrenches, electric and pneumatic screwdrivers, ball drivers, lifting equipment, computers, oscilloscopes, voltage and current probes, multimeters, micrometers, and calipers.
Optical fibers, spectrometers, and power meters used to obtain and analyze results during functional testing and qualification.
Performed root cause analysis on production issues with the SAP system, Opti Angle, and YieldStar software. Developed corrective actions and monitored results. Partnered with engineering teams on structured 8D workflows for electromechanical and optical anomalies.
Assisted with making recommended changes in design, methods, and procedures to enhance product quality. Developed Excel spreadsheets to track key performance indicators on the production floor.
Maintained accurate process and inspection documentation supporting traceability, change control, and continuous improvement.
Participated in cross-functional teams with manufacturing, quality, and procurement departments. Sub-assembly handoff to test; partnership with Production Engineering on escalations.
Worked in a cleanroom environment under strict safety procedures and ASML 5S+1 requirements. Wore coveralls, hoods, booties, safety glasses, and gloves for the entire duration of 12-hour night shifts.
Contamination control, ESD discipline, tolerance control, change control, and traceability across the build, qualification, and handoff cycle.
This role gave direct exposure to ASML production scanner build, alignment, qualification, and diagnostic workflows on the Wilton manufacturing floor, one of ASML's main global manufacturing tech hubs for wafer alignment sensors and DUV/EUV sub-systems. The contamination, ESD, and tolerance discipline required is comparable to fab module qualification, and the cross-functional cadence between manufacturing and production engineering directly informs how I approach quality and inspection work today at General Dynamics Electric Boat.