Thermal Spray Process Engineer

IBC Materials & Technologies•Lebanon, IN

32d•Onsite

About The Position

IBC Group is an industrial solutions provider specializing in advanced metal coatings, component repair, and performance engineering. We partner with manufacturers to extend the life of critical equipment, improve performance, and solve challenges related to wear, corrosion, and durability. Our capabilities include a wide range of thermal spray and performance coating technologies, supported by metallurgical expertise to ensure solutions meet demanding specifications. From restoring worn components to enhancing new parts, our work helps customers reduce downtime and improve reliability across a variety of industries. IBC Group operates focused on leveraging advanced surface engineering solutions globally. IBC Group is an equal opportunity employer. Full-time employees qualify for additional benefits like medical, vision, and dental insurance, paid time off (i.e. vacation), and retirement savings options. We are seeking an experienced Thermal Spray Process Engineer to support and improve thermal spray coating operations in a manufacturing environment. This position is responsible for process development, production support, process documentation, quality improvement, troubleshooting, customer support, and continuous improvement initiatives related to thermal spray technologies. The ideal candidate will have strong hands-on and technical experience with multiple thermal spray processes, including HVOF, Plasma Spray, Flame Spray, and Twin-Wire Arc Spray systems. Crucially, this individual must possess the ability to lead end-to-end technical projects related to component parts repair—orchestrating everything from pre-machining and surface prep to thermal spray application and final post-machining operations (including precision grinding). This role works closely with production, customers, and leadership to ensure coating performance, operational efficiency, and compliance with customer and industry requirements. Due to ITAR and customer compliance requirements, candidates must be either a U.S. Citizen or U.S. Permanent Resident (Green Card Holder).

Requirements

Must be a U.S. Citizen/Green Card holder. Sponsorship is not provided for this position.
Bachelor’s degree in Materials Engineering, Metallurgical Engineering, Mechanical Engineering, Manufacturing Engineering, or a related engineering discipline is required.
A minimum of 5 years of engineering experience in thermal spray or related coatings technologies is required.
Demonstrated hands-on experience with HVOF, Plasma Spray, Flame Spray, and Twin-Wire Arc Spray operations.
Solidworks or equivalent 3-D modeling software experience is required.
Strong communication skills with a proven ability to train operators, lead technical projects cross-functionally, and collaborate across departments.
Must have excellent organizational and project management skills.
Must be proficient in Microsoft Office software.
Ability to work in a manufacturing environment with exposure to noise, heat, dust, and industrial equipment.
Ability to stand, walk, bend, and lift up to 50 pounds occasionally.
Ability to wear required PPE, including respirators, eye, and hearing protection when necessary.

Nice To Haves

Experience operating, troubleshooting, and optimizing industrial thermal spray equipment is strongly preferred.
Strong understanding of coating properties, metallurgy, surface preparation, masking, and crucial finishing operations (including pre- and post-coat machining and grinding tolerances).
Proven experience troubleshooting thermal spray processes and complex coating quality issues.

Responsibilities

Develop, optimize, and maintain thermal spray coating processes for production and new customer applications.
Provide core technical expertise for HVOF (High Velocity Oxygen Fuel), Plasma Spray, Flame Spray, and Twin-Wire Arc Spray systems.
Lead comprehensive technical projects focused on industrial parts repair, successfully managing the full sequence of operational steps including necessary pre-machining, thermal spray coating, and precision post-machining/grinding.
Troubleshoot coating, equipment, and process issues to improve quality, repeatability, and throughput.
Perform daily contract review on incoming jobs, creating precise process instructions in the ERP system for production staff to follow.
Support production teams with process parameters, work instructions, operator training, and process controls, taking a primarily hands-on approach.
Design fixturing and masking for customer parts as needed.
Read, interpret, and create blueprints, technical drawings, schematics, and computer-generated reports.
Perform coating evaluations, root cause investigations, and metallurgical analysis to identify process improvements and resolve customer issues.
Assist with equipment evaluations, maintenance coordination, and capital improvement projects.
Serve as the primary technical resource for customers regarding coating selection, process capabilities, feasibility assessments, and root cause investigations.
Follow all AS9100/ISO 9001 standards, internal quality policies, OSHA safety regulations, and company safety policies.
Complete additional assignments and projects as prescribed by your supervisor.