Process Engineer

Biolyst Scientific • Caernarvon Township, PA

23h • Onsite

About The Position

We are seeking an experienced Thermal Evaporation Process Engineer to own and continuously improve thermal evaporation (resistive) processes within our C-Flat operations. The successful candidate will develop, characterize, optimize, and sustain high-quality Carbon thin-film deposition processes for C-Flat TEM Grid production. This hands-on engineering role combines process development, equipment ownership, data-driven troubleshooting, and cross-functional collaboration to achieve yield, throughput, and performance targets.

Requirements

• Bachelor's degree in Materials Science, Chemical Engineering, Physics, Electrical Engineering, Mechanical Engineering, or related field.
• 3–8+ years of hands-on experience with thermal evaporation processes (resistive heating and/or Sputtering) in a production, pilot, or R&D setting.
• Strong understanding of vacuum technology, deposition kinetics, material evaporation behavior, and factors affecting film quality (uniformity, stoichiometry, defects).
• Proficiency in data analysis and statistical methods (JMP, Minitab, Python/R, or similar).
• Demonstrated problem-solving skills using structured methodologies (8D, fishbone, 5-Why, DOE).
• Strong hands-on aptitude in cleanroom/vacuum environments.
• Excellent analytical, experimental design, and data interpretation skills.
• Ability to work independently and collaboratively in a fast-paced, dynamic environment.
• Detail-oriented with strong documentation and communication skills (written reports, presentations, work instructions).
• Commitment to safety and quality standards.

Nice To Haves

• Familiarity with complementary thin-film technologies (sputtering, ALD, CVD, IBS) — a plus.
• Knowledge of semiconductor, optical thin films, OLED/LED, photovoltaics, or MEMS fabrication environments.
• Experience qualifying new evaporation materials/sources.
• Prior equipment ownership or process transfer experience in high-volume manufacturing.

Responsibilities

• Serve as process owner for thermal evaporation tools (resistive gun deposition and sputtering), including recipe development, parameter optimization (source temperature, deposition rate, vacuum level, source-to-substrate geometry, etc.), and qualification of new materials/evaporation sources.
• Design and execute Design of Experiments (DOE) to characterize film properties (thickness uniformity, adhesion, and establish process windows.
• Develop and document detailed process specifications, Work Instructions (WI), Standard Operating Procedures (SOP), and FMEA documentation.
• Perform preventive maintenance, upgrades, and qualification of new evaporation systems or sources.
• Partner with R&D, product development, quality, and production teams to transfer new processes from development to high-volume manufacturing.
• Perform hands-on operation and troubleshooting of high-vacuum thermal evaporation chambers (cryo-pumped or turbo-pumped systems).
• Drive continuous improvement projects targeting film quality, deposition rate, material utilization, cycle time, defect reduction, and cost of ownership.
• Support yield enhancement, cost reduction, and new product introduction initiatives.
• Ensure compliance with safety, quality, and environmental standards in a cleanroom/production environment.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level