Senior Process Development Engineer Jobs in Morgan Hill, CA

WHO WE ARE

Together we are a world-class diversified manufacturer with a commitment from our team to proudly provide pure precision solutions to our customers, delivering superior quality, value, and service.

Ferrotec (USA) Corporation is a technology company with a worldwide presence in various end products, manufacturing systems, and industries serving primarily the semiconductor industry. We provide our customers with advanced materials, components, systems, and manufacturing solutions. Please visit www.ferrotec.com for a list of office locations.

HOW YOU MAKE AN IMPACT

The Senior Process Development Manager is a hands-on technical leader responsible for advancing thin film

deposition processes and supporting customer success using Physical Vapor Deposition (PVD) technologies, including sputtering and evaporation.

This role combines deep technical expertise, direct tool operation, and customer engagement with lightweight team leadership responsibilities. The position leads a small team of scientists and engineers while remaining actively involved in day-to-day experimental work, system operation, customer demonstrations, and process development execution.

Success in this role requires the ability to independently run deposition systems and metrology tools, collaborate across engineering and sales teams, and directly support customers through process development, troubleshooting, and system acceptance activities.

This position reports to the Managing Director - Thin Films Solutions Business.

WHAT SUCCESS LOOKS LIKE

Technical & Hands-On Leadership (Primary Focus)

• Independently operate PVD systems (sputtering, evaporation) end-to-end, including system setup, execution, troubleshooting, and maintenance adjustments.
• Design, execute, and analyze thin film deposition experiments with minimal support.
• Develop deep process understanding, including how key variables (pressure, power, rate, geometry, etc.) impact film properties.
• Utilize DOE, SPC, and modeling approaches to optimize processes and troubleshoot issues.
• Operate and interpret metrology tools (minimum: profilometry; preferred: ellipsometry, SEM, AFM, 4-point probe) with full understanding of applicability and limitations.
• Apply modeling and simulation to improve deposition performance and system design.

Customer-Facing Execution

• Lead customer demonstrations, including configuring systems, running processes, and adjusting hardware/software in real time.
• Execute multi-day customer acceptance tests (CAT) and prove system performance against specifications.
• Serve as the primary technical interface for customer process development activities.
• Translate customer requirements into process solutions and guide specification tradeoffs.
• Provide onsite or remote customer support for process-related issues and field troubleshooting.

Process Development & R&D

• Lead development of new or improved thin film deposition processes and equipment capabilities.
• Generate experimental plans, execute testing, and deliver clear, data-driven results and recommendations Identify new applications and technology opportunities aligned with business strategy.
• Transfer developed processes into production and customer environments.

Cross-Functional Collaboration

• Partner closely with Sales, Applications, and Engineering teams to align technical solutions with customer needs.
• Support commercialization of new technologies and systems.
• Contribute to technical proposals and customer engagements.

Team Leadership (Lightweight)

• Manage and mentor a small team of scientists and engineers.
• Set priorities, ensure execution, and maintain team effectiveness without heavy administrative overhead.
• Act as a technical leader and escalation point, stepping in directly when needed to ensure continuity and delivery.

Operational Excellence

• Ensure readiness and reliability of lab systems for internal work and customer demos.
• Maintain a strong safety culture and compliance with all safety practices.
• Document processes, experiments, and results clearly and effectively.

Not a comprehensive list of duties. Duties may change without notice at management's sole discretion

WHAT YOU NEED TO BE SUCCESSFUL

• M.S. or Ph.D. in Engineering, Physics, Materials Science, or related field.
• 10-15+ years of recent, hands-on experience in thin film deposition, specifically PVD (sputtering and/or evaporation).
• Proven ability to independently operate deposition systems and metrology tools.
• Strong understanding of process physics and ability to troubleshoot deposition issues at a fundamental level.
• Experience running experiments and analyzing results using DOE/SPC methodologies.
• Demonstrated ability to work directly with customers in technical environments.
• Mechanical aptitude to adapt, configure, and troubleshoot equipment for demonstrations and experiments.
• Experience executing customer-facing work (e.g., demos, acceptance testing, process validation.

Preferred Skills:

• Experience supporting field/application issues and diagnosing coating/process failures.
• Strong research capability: ability to interpret literature and translate into experiments.
• Knowledge of key application areas (e.g., photonics, semiconductor devices, advanced coatings).
• Experience guiding customers on specifications and process trade-offs.
• Familiarity with modeling tools (MATLAB, Python, Mathematica).
• Experience contributing to business development or bridging technical and commercial teams.
• Conference presentations or industry visibility.

PERKS OF JOINING OUR TEAM

With positive values, a productive atmosphere, and a commitment to excellence, Ferrotec encourages employees to maximize and realize their potential.

The salary range included in this job posting is relevant to applicants who reside or work in the Livermore, CA area only. Salary offers will depend on experience, knowledge, skills, education, and location. Actual salary may vary due to these and other factors.

Ferrotec is proud to offer a Competitive Benefits Package including Medical, Dental, Vision, Life & Disability, 401K Matching, Flexible Work Hours, Tuition Reimbursement, Leadership Development, Travel and Hotel Discounts, Paid Time Off, Sick & Wellness and Volunteer Time, Employee Recognition Program, Employee Engagement & Appreciation Events hosted throughout the year. Virtual Wellness Activities and Classes are available to all employees & family members and Much More!

We would love to get to know you better and you get to know us better! You can easily apply!

Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, pregnancy, genetic information, disability, status as a protected veteran, or any other protected category under applicable federal, state, and local laws.