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Senior Process Development Engineer Jobs in Sunnyvale, CA

Teledyne

Process Development Engineer

Mountain View, CA · Hybrid

$72K - $96K/yr

... development, oceanographic research, deepwater oil and gas exploration and production, medical ... Provide process engineering support for thin-film hybrid assembly and MIC processes * Support ...

GeneFab

Senior Process Engineer, MSAT

Alameda, CA · On-site

$150 - $185/hr

Senior Process Engineer, MSATGeneFab Alameda, California, United States About this position About ... Collaborate closely with Process Development to evaluate platform candidates, align on scalable ...

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Senior Process Development Engineer information

See Sunnyvale, CA salary details

$88K

$142.1K

$200.1K

How much do senior process development engineer jobs pay per year?

As of Sep 2, 2026, the average yearly pay for senior process development engineer in Sunnyvale, CA is $142,148.00, according to ZipRecruiter salary data. Most workers in this role earn between $122,100.00 and $157,900.00 per year, depending on experience, location, and employer.

What does a senior process development engineer do?

A Senior Process Development Engineer is responsible for designing, developing, and optimizing manufacturing processes to improve efficiency, quality, and cost-effectiveness. They often lead teams in scaling up processes from the laboratory to full production, troubleshoot technical issues, and implement new technologies or methods. Additionally, they collaborate with cross-functional teams, including R&D, quality assurance, and production, to ensure processes meet regulatory and safety standards. Their expertise helps companies maintain competitive advantages and meet production goals.

What are the key skills and qualifications needed to thrive as a senior process development engineer?

To thrive as a Senior Process Development Engineer, you need a strong background in chemical or mechanical engineering, process optimization, and project management, typically supported by a relevant engineering degree. Familiarity with CAD software, process simulation tools (such as Aspen Plus or MATLAB), and Six Sigma or Lean Manufacturing certifications is often required. Excellent problem-solving, leadership, and communication skills help you coordinate cross-functional teams and drive continuous improvement. These skills are crucial for developing efficient, scalable processes that meet quality standards and business goals.

What are some common challenges a senior process development engineer may face when scaling up a new process from the lab to full production?

Senior Process Development Engineers often encounter challenges such as maintaining product quality and consistency when transitioning from small-scale laboratory experiments to large-scale manufacturing. This process typically involves troubleshooting equipment limitations, optimizing process parameters, and ensuring compliance with safety and regulatory standards. Effective collaboration with cross-functional teams, such as R&D, manufacturing, and quality assurance, is crucial to address these challenges and achieve a smooth scale-up. Adaptability and problem-solving skills are essential to navigate unexpected issues that may arise during this transition.

What is the difference between Senior Process Development Engineer vs Process Engineer?

AspectSenior Process Development EngineerProcess Engineer
CredentialsBachelor's or Master's in Chemical, Mechanical, or Industrial Engineering; experience in process developmentBachelor's degree in Engineering or related field; entry to mid-level experience
Work EnvironmentResearch and development labs, manufacturing facilities, cross-functional teamsManufacturing plants, production lines, process optimization teams
Industry UsagePharmaceuticals, chemicals, biotech, manufacturingManufacturing, chemical processing, consumer goods

The main difference is that Senior Process Development Engineers focus on developing and optimizing new processes, often in R&D settings, while Process Engineers typically oversee existing manufacturing processes to improve efficiency and quality. Senior roles involve more strategic planning and innovation, whereas Process Engineers focus on day-to-day process operations.

What are popular job titles related to Senior Process Development Engineer jobs in Sunnyvale, CA?

For Senior Process Development Engineer jobs in Sunnyvale, CA, the most frequently searched job titles are:

What job categories do people searching Senior Process Development Engineer jobs in Sunnyvale, CA look for?

The top searched job categories for Senior Process Development Engineer jobs in Sunnyvale, CA are:

What cities near Sunnyvale, CA are hiring for Senior Process Development Engineer jobs?

Cities near Sunnyvale, CA with the most Senior Process Development Engineer job openings:

Senior Process Development Engineer jobs near you
Infographic showing various Senior Process Development Engineer job openings in Sunnyvale, CA as of August 2026, with employment types broken down into 1% As Needed, 83% Full Time, 13% Part Time, and 3% Contract. Highlights an 87% Physical, 3% Hybrid, and 10% Remote job distribution, with an average salary of $142,148 per year, or $68.3 per hour.

Sr. Process Development Manager

Ferrotec (USA) Corporation

Livermore, CA • On-site

$130K - $170K/yr

Full-time

Medical, Dental, Vision, Life, Retirement, PTO

Re-posted 24 days ago

Job description

Description
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.

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