Senior Process Engineer, IBS Coating Group

Edmund Optics•Oldsmar, FL

22d•Onsite

About The Position

The primary responsibility of the Senior Process Engineer’s (SPE) is to support Engineering activity within the Ion Beam Sputtering (IBS) Coating Cell of our Florida facility. The SPE will support both ongoing Production - with custom coating designs, fixtures and process troubleshooting – as well as R&D activities, to develop new processes and materials for advanced product requirements. This person will have ownership of the IBS Deposition Systems together with all associated metrology, having responsibility for its maintenance, upkeep, documentation and training. IBS equipment is typically used for optical coatings that have hundreds of layers and run over multiple days, so reliable equipment and robust processes are paramount. The SPE will also be part of the Factory Quote Team, providing feasibility assessments and cost estimates for customer RFQs. A second area of responsibility will be to provide back-up engineering support for the E-Beam Coating area. The SPE will use the principles of LEAN 6σ and 6S to develop and execute a continuous improvement program for IBS production processes. This person is self-directed and can work independently.

Requirements

In depth understanding of High Vacuum Systems, associated pumps, sub-assemblies and control equipment.
Familiarity with vacuum diagnostics using residual gas analysis and leak detection.
Working knowledge of IBS components such as ion sources, grids, power supplies and target assemblies
Understanding of Broad Band Optical Monitoring (BBOM) principles
Good working knowledge of OptiLayer or equivalent commercial thin film design software.
Familiarity with various models for the characterization of optical materials, such as Cauchy, Sellmeier and Lorentz.
Ability to use software for reverse engineering to assess thickness errors from spectral measurements.
Familiarity with standard techniques to improve non-uniformity, such as chamber geometry and shadow masking.
Working knowledge of advanced metrology equipment, such as spectrophotometers, Cavity Ring Down Spectroscopy (CRDS), White Light Interferometer, photothermal common-path interferometry (PCI)
Knowledge of factors affecting Laser Induced Damage Threshold (LIDT) such as material selection, coating design, substrate and cleanliness, for both nanosecond and femtosecond regimes
Understand all aspects of blueprints including geometric dimensioning and tolerancing (GD&T)
Proficient in CAD software; proficiency in SolidWorks is a plus
Working knowledge of LEAN 6σ principles and DOE
Ability to think critically and solve complex problems
Excellent math, verbal and written skills
Understand conventional manufacturing and metrology techniques for precision optics
Intermediate to advanced mechanical and computer skills. (Excel, Word, PowerPoint, Vizio, SQL)
US Citizenship or Permanent Residence required
Bachelors of Science degree in Engineering or technical discipline; or, equivalent experience in the Thin Film Manufacturing Industry.
Ability to sit or stand for long periods; ability to travel; adequate manual dexterity to perform essential functions; ability to use some physical efforts in the handling of heavy materials and machinery; ability to lift ≥50 lbs.; ability to work in manufacturing environment

Responsibilities

Operate, maintain, troubleshoot and improve vacuum deposition equipment for IBS coatings.
Train technicians in operation and maintenance of such equipment.
Develop preventive maintenance schedules to avoid unscheduled downtime.
Liaise with equipment manufacturer to implement software and hardware upgrades as necessary.
Design substrate holders (fixtures) for both routine shapes and custom parts
Use commercial software to design complex multilayer coatings for demanding specifications, including laser damage, polarization and GDD control for Ultrafast applications.
Characterize materials for optical properties to a high degree of accuracy and evaluate their variation and evolution over time.
Specify and optimize metrology to measure critical coating performance: R, T, GDD, Loss, Absorption. Train technicians in accurate operation of this equipment.
Conduct experiments to evaluate Cp and Cpk for IBS processes using Lean Six Sigma, and DOE methodologies
Develop a Critical Materials List with primary and secondary suppliers.
Supervise the creation of routings, SOP’s, WI’s, etc.
Review RFQs with the IBS Quote Team and either complete or reassign to other members of the department
Specify new equipment and tools to increase capability and/or capacity
Based on need, become proficient in equipment and processes outside of area-of-focus
Generate detailed reports for both custom production work (FAIs) and R&D activity.
Participate in bringing new technology or processes from Pilot to Production
May be required to use shop and power tools to modify parts or equipment
Comply with federal, state, and company policies, procedures, and regulations