Senior Metrology Engineer Tech Manufacturing

Senior Metrology Engineer

Location:

Roanoke, VA, US

Full‑time, Direct Hire, 9/80 Schedule

We’re seeking a Senior Metrology Engineer to join a leading defense technology organization supporting advanced electronic warfare programs. This is a highly technical role for someone who wants to serve as a subject matter expert in surface characterization, working across cutting‑edge analytical instrumentation to support materials development, process optimization, and fundamental surface‑science research.

This position offers relocation assistance, a sign‑on bonus, and reimbursed travel for onsite interviews. We welcome candidates open to relocating to the Roanoke, VA area.

• Operate, maintain, and develop measurement protocols for XPS, SEM, AFM, Auger spectroscopy, LEED, RHEED, and other surface analysis tools
• Design and execute detailed experiments to characterize materials, coatings, interfaces, and thin films
• Analyze complex data sets, applying advanced quantitative methods to extract meaningful physical and chemical insights
• Interpret results using deep expertise in surface science, surface chemistry, and materials science
• Troubleshoot instrumentation, coordinate maintenance, and ensure high measurement quality and repeatability
• Collaborate cross‑functionally with R&D, product development, and manufacturing teams on material investigations and root cause analysis
• Document methods and results clearly for internal and external stakeholders
• Contribute to continuous improvement of analytical workflows and experimental methodology
• Define calibration standards, metrology capability roadmaps, and long‑term measurement system improvements
• Evaluate, select, and qualify new metrology equipment, technologies, and software systems

• PhD in Materials Science, Chemistry, Physics, or a related field — OR MS with 3+ years of relevant experience — OR BS with 6+ years of relevant experience
• Hands‑on proficiency with XPS, SEM, AFM, Auger spectroscopy, UPS, and LEED/RHEED
• Demonstrated expertise in data analysis and advanced interpretation of surface analysis results
• Strong foundation in surface science, surface chemistry, or materials science
• Ability to work independently and collaboratively across multidisciplinary teams
• Excellent problem‑solving, communication, and documentation skills

• Experience in aerospace, defense, or other high‑precision, regulated industries
• Background in automated inspection systems, robotic metrology, or digital thread/Model‑Based Definition environments
• Experience leading metrology capability development or technology road mapping
• Lean/continuous improvement certification (e.g., Six Sigma Green Belt or higher)

• Must be able to obtain a security clearance
• Background check and drug screening required
• Onsite interview required

USPRO is an equal opportunity employer and will consider all applicants for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, veteran, disability and/or other protected categories. We are also committed to providing reasonable accommodation(s) to qualified individuals with disabilities or needs, as required by law.