Thermal Spray Process Engineer
Job in
Lebanon, Boone County, Indiana, 46052, USA
Listing for:
IBC MATERIALS & TECHNOLOGIES, LLC
Full Time
position
Listed on 2026-06-07
Job specializations:
-
Engineering
Process Engineer, Manufacturing Engineer, Quality Engineering
-
Manufacturing / Production
Manufacturing Engineer, Quality Engineering
Salary/Wage Range or Industry Benchmark: 75000 - 95000 USD Yearly
USD
75000.00
95000.00
YEAR
Job Description & How to Apply Below
Benefits
- 401(k)
- 401(k) matching
- Dental insurance
- Health insurance
- Paid time off
About the Company
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.
Position Summary
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).
Essential Duties and Responsibilities Process Development: Develop, optimize, and maintain thermal spray coating processes for production and new customer applications.Technical Expertise: Provide core technical expertise for HVOF (High Velocity Oxygen Fuel), Plasma Spray, Flame Spray, and Twin-Wire Arc Spray systems.Project Leadership & Parts Repair: 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.Troubleshooting: Troubleshoot coating, equipment, and process issues to improve quality, repeatability, and throughput.Contract Review: Perform daily contract review on incoming jobs, creating precise process instructions in the ERP system for production staff to follow.Production Support: Support production teams with process parameters, work instructions, operator training, and process controls, taking a primarily hands-on approach.Tooling & Design: Design fixturing and masking for customer parts as needed.Technical Documentation: Read, interpret, and create blueprints, technical drawings, schematics, and computer-generated reports.Metallurgical Analysis: Perform coating evaluations, root cause investigations, and metallurgical analysis to identify process improvements and resolve customer issues.Capital Improvements: Assist with equipment evaluations, maintenance coordination, and capital improvement projects.Customer Interface: Serve as the primary technical resource for customers regarding coating selection, process capabilities, feasibility assessments, and root cause investigations.Quality Compliance: Follow all AS9100/ISO 9001 standards, internal quality policies, OSHA safety regulations, and company safety policies.General Assignments: Complete additional assignments and projects as prescribed by your supervisor.Job Requirements
Citizenship: Must be a U.S. Citizen/Green Card holder. Sponsorship is not provided for this position.Education: Bachelor’s degree in Materials Engineering, Metallurgical Engineering, Mechanical Engineering, Manufacturing Engineering, or a related engineering discipline is required.Experience: A minimum of 5 years of engineering experience in thermal spray or related coatings technologies is required.Technology
Competency:
Demonstrated hands-on experience with HVOF, Plasma Spray, Flame Spray, and Twin-Wire Arc Spray operations.Equipment Know-How: Experience operating, troubleshooting, and optimizing industrial thermal spray equipment is strongly preferred.Manufacturing Process Depth: Strong understanding of coating properties, metallurgy, surface preparation, masking, and crucial finishing operations (including pre- and post-coat machining and grinding…
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