R&D Roll Coating Engineer – Thin Film Optics

R&D Roll Coating Engineer – Thin-Film Optics

The R&D Roll Coating Engineer plays a key role in developing next-generation thin-film optical materials through advanced roll-to-roll coating technologies. This role focuses on early-stage formulation evaluation, process development, and prototyping of precision optical films used in cutting-edge optical systems, displays, sensors, and photonic components. The engineer will work hands-on in the lab and pilot line to develop scalable coating processes, characterize thin-film performance, and translate experimental findings into robust manufacturing pathways.

Key Responsibilities

• Develop, refine, and validate roll-to-roll coating processes for advanced thin-film optical materials.
• Design and execute structured experiments (DOE) to explore process-material interactions and determine optimal coating conditions for experimental formulations.
• Conduct feasibility studies to assess new coating chemistries, equipment configurations, and process technologies for future optical product platforms.

Thin-Film Characterization & Analysis

• Evaluate thin-film thickness, uniformity, refractive index, optical transmission/absorption, and surface morphology using metrology tools such as profilometry, ellipsometry, AFM, microscopy, and spectrophotometry.
• Analyze defects and film anomalies and identify root causes through materials, mechanical, or process-related investigations.

Coating Technology Expertise

• Develop new coating strategies for multi-layer optical stacks, nanostructured films, high-precision functional layers, or specialty surface treatments.

Pilot-Line Development & Scale-Up

• Conduct hands-on trials on pilot roll-to-roll equipment to validate newly developed processes.
• Translate laboratory findings into scalable processes and establish the groundwork for manufacturing transfer.
• Identify constraints or risks associated with scale-up and propose design or formulation modifications to improve manufacturability.

Cross-Functional Collaboration

• Work closely with equipment engineering, quality engineering, and manufacturing technology teams to advance new product concepts.
• Communicate experimental results, insights, and recommendations through technical reports, presentations, and data summaries.
• Contribute to design reviews, technology roadmaps, and development milestones for emerging optical products.

Documentation & Method Development

• Develop process documentation, experimental protocols, and early-phase control strategies for new coatings and formulations.
• Maintain accurate experimental records, process parameters, lab notebooks, and data sets to support reproducibility and long-term research continuity.

Pre-Requisites / Skills / Experience Requirements

Qualifications:

• Bachelor's degree in Chemical Engineering, Materials Engineering, Mechanical Engineering, Optics, or related technical field.
• 5–10 years of relevant experience in roll-to-roll coating or thin-film development within R&D or advanced materials environments.
• Experience performing structured experiments (DOE), data analysis, and root-cause investigations.
• Proficiency with analytical tools such as Minitab, JMP, or Python-based analysis.
• Must be U.S. Persons as defined by ITAR. ITAR defines a U.S. Person as a U.S. Citizen, U.S. Permanent Resident (i.e. "Green Card Holder"), Political Asylee, or Refugee.

Preferred:

• Experience developing thin-film optical materials, multilayer optical stacks, interference coatings, polarization films, or related technologies.
• Familiarity with optical metrology and thin-film characterization techniques.
• Experience working in cleanroom or contamination-controlled environments.
• Current DOD clearance

If you have what it takes to push boundaries and seize opportunities, apply to join our team today.

VIAVI Solutions is an equal opportunity and affirmative action employer – minorities/females/veterans/persons with disabilities.

Job Posting Pay Range: 101,500 to 188,500. Exceptional qualifications, experience and location may impact salary. VIAVI offers a competitive benefits package that includes paid time off, health, life and disability insurance, 401(k), and a bonus program.