Process Engineer

Job Title:

C-Flat process engineer

Manufacturing - Location - Morgantown, PA

Reports to:

COO

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.

• 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.

• 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).

• 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.

• 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.

Biolyst Scientific provides equal employment opportunities to all persons and prohibits employment decisions based on race, religion, color, creed, national origin, sex, age, disability, political affiliation, protected veteran status, or sexual orientation.