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Senior Pvd Process Engineer Jobs in Madison, WI (NOW HIRING)

Mastermold LLC

Paint Process Engineer

Johnson Creek, WI · On-site

$90K - $108K/yr

Opportunities for growth into senior process engineering, project engineering, or leadership roles. * A visible impact: you'll see your process changes show up directly as better quality, less scrap ...

Mastermold LLC

Paint Process Engineer

Johnson Creek, WI · On-site

$90K - $108K/yr

Opportunities for growth into senior process engineering, project engineering, or leadership roles. * A visible impact: you'll see your process changes show up directly as better quality, less scrap ...

Illumina, Inc.

Process Engineer II

Madison, WI · On-site

You will drive process performance through process development and design, data-driven ... Desire to grow toward a Senior Engineer role by leading complex cross-functional projects from ...

Illumina, Inc.

Process Engineer II

Madison, WI · On-site

You will drive process performance through process development and design, data-driven ... Desire to grow toward a Senior Engineer role by leading complex cross-functional projects from ...

AprilAire

Senior Automation Engineer

Madison, WI · On-site

$104K - $137K/yr

This role serves as a system-level integrator, ensuring mechanical, controls, and process elements ... The Senior Automation Engineer supports projects from early design review through implementation ...

AprilAire

Senior Automation Engineer

Madison, WI

$104K - $137K/yr

This role serves as a system-level integrator, ensuring mechanical, controls, and process elements ... The Senior Automation Engineer supports projects from early design review through implementation ...

AprilAire

Senior Automation Engineer

Madison, WI · On-site

$104K - $137K/yr

This role serves as a system-level integrator, ensuring mechanical, controls, and process elements ... The Senior Automation Engineer supports projects from early design review through implementation ...

Actalent

Sr. Product Engineer

Lodi, WI · On-site

$100K - $110K/yr

Job Title Sr. Product Engineer The Sr. Product Engineer serves as the technical owner of a major ... Work on highly customized industrial food processing equipment, ensuring designs meet industry ...

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All JobsPvd Process Engineer JobsSenior Pvd Process Engineer JobsSenior Pvd Process Engineer Jobs in Madison, WI

Senior Pvd Process Engineer information

See Madison, WI salary details

$75.6K

$122K

$171.8K

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

As of Aug 6, 2026, the average yearly pay for senior pvd process engineer in Madison, WI is $122,040.00, according to ZipRecruiter salary data. Most workers in this role earn between $104,800.00 and $135,500.00 per year, depending on experience, location, and employer.

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

AspectSenior Pvd Process EngineerPvd Process Engineer
ExperienceTypically 5+ years in PVD processesEntry to mid-level experience in PVD processes
ResponsibilitiesLeading process development, troubleshooting, mentoringExecuting process setups, monitoring, and basic troubleshooting
CertificationsRelevant certifications often preferredBasic industry certifications may suffice
Work EnvironmentManufacturing facilities, R&D labsManufacturing facilities, R&D labs

The main difference between a Senior Pvd Process Engineer and a Pvd Process Engineer lies in experience, responsibilities, and leadership. Senior engineers typically lead process development and mentor junior staff, while Pvd Process Engineers focus on executing and monitoring processes. Both roles work in similar environments within manufacturing and R&D settings, but the senior role requires more expertise and oversight.

What is a senior PVD process engineer?

Senior PVD (Physical Vapor Deposition) Process Engineers are professionals who develop, optimize, and oversee thin film deposition processes typically used in semiconductor, electronics, or materials manufacturing. They are responsible for ensuring the quality and efficiency of PVD equipment and processes, troubleshooting issues, and implementing improvements. These engineers often collaborate with cross-functional teams to support product development and manufacturing needs, and they may also lead process integration and scale-up activities. Their expertise is crucial in maintaining high-yield and reliable production environments.

What are the key skills and qualifications needed to thrive as a senior PVD process engineer, and why are they important?

To thrive as a Senior PVD Process Engineer, you need a solid background in materials science, thin film deposition, and semiconductor manufacturing, usually backed by a relevant engineering degree and industry experience. Familiarity with PVD (Physical Vapor Deposition) systems, process control software, and statistical process control (SPC) tools is typically required. Strong analytical thinking, problem-solving abilities, and effective communication skills help you lead projects and collaborate with cross-functional teams. These skills are crucial for optimizing manufacturing processes, ensuring product quality, and driving innovation in a highly technical and fast-evolving industry.

How does a senior PVD process engineer typically collaborate with cross-functional teams during process development and troubleshooting?

As a Senior PVD Process Engineer, you’ll frequently work alongside R&D, equipment engineering, and manufacturing teams to develop and optimize thin film deposition processes. Collaboration often involves joint problem-solving during process qualification, equipment upgrades, and yield improvement initiatives. Clear communication skills are essential, as you’ll be responsible for conveying technical findings, aligning process requirements, and leading cross-functional meetings to ensure smooth integration of new technologies into production. This collaborative environment offers opportunities to mentor junior engineers and influence the direction of process innovation.
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Senior Pvd Process Engineer jobs near you
Infographic showing various Senior Pvd Process Engineer job openings in Madison, WI as of August 2026, with employment types broken down into 1% As Needed, 78% Full Time, 16% Part Time, 4% Contract, and 1% Nights. Highlights an 92% Physical, 2% Hybrid, and 6% Remote job distribution, with an average salary of $122,040 per year, or $58.7 per hour.

Paint Process Engineer

Mastermold LLC

Johnson Creek, WI • On-site

$90K - $108K/yr

Full-time

Medical, Dental, Vision, Retirement, PTO

Re-posted 5 hours ago

Job description


We’re looking for Paint Process Engineers to own, stabilize, and improve our paint and coating processes. This role is less about “babysitting the line” and more about building robust processes that run right the first time, every time.

You’ll define standards, dial in parameters, reduce defects, and lead continuous improvement so production, quality, and maintenance have a repeatable, capable process to work with.


What You’ll Do

Process Engineering & Standardization

  • Develop, document, and maintain paint process standards (parameters, recipes, and work instructions) for existing and new products.

  • Define and optimize: gun settings, atomizing air, film build targets, flash/bake times, oven profiles, line speeds, and booth balance.

  • Build and maintain control plans, standardized work, and process check sheets for paint operations.

  • Use data (SPC, Pareto, capability studies) to identify variation and tighten up the process.

Defect Reduction & Root Cause Analysis

  • Lead structured problem-solving for paint defects (runs, sags, orange peel, dry spray, fisheyes, adhesion issues, color shifts, etc.).

  • Perform root cause analysis using tools like 5-Why, Fishbone, PDCA, and implement permanent corrective actions.

  • Partner with Quality to monitor scrap, rework, and first-pass yield, and drive projects to reduce defects.

Launches, Trials & Process Changes

  • Lead process development for new colors, coatings, or products—from lab trials to full production.

  • Plan and run process trials and DOE to evaluate new materials, equipment, and parameter changes.

  • Support PPAPs and customer approvals by preparing data, documentation, and sample runs as needed.

Cross-Functional Collaboration

  • Work closely with Production, Maintenance, Engineering, and Quality to ensure the paint process is understood, stable, and repeatable.

  • Train supervisors, leads, and operators on proper application techniques, defect recognition, and process controls.

  • Collaborate with Maintenance/Engineering on equipment upgrades, nozzle/robot changes, and oven/booth improvements.

Safety & Compliance

  • Ensure paint processes meet safety, environmental, and regulatory requirements.

  • Support safe storage, handling, and usage of paints, solvents, and chemicals used in the process.


What You Bring

Required

  • Bachelor’s degree in Chemical, Mechanical, Industrial, or Manufacturing Engineering
    OR equivalent hands-on experience in paint/coatings process engineering.

  • Direct experience with industrial painting or coating operations (automotive, heavy truck, agriculture, metal finishing, composites, etc.).

  • Strong process engineering mindset: comfortable with data, parameters, standardized work, and root cause analysis.

  • Ability to operate on the production floor, communicate with operators, and present clearly to leadership.

  • Proficiency with Excel and basic data analysis for reporting and process monitoring.

Preferred

  • Experience with powder coating, liquid paint, or gel coat systems, including pretreatment and curing ovens.

  • Familiarity with DFT measurement, gloss/color measurement, adhesion testing, and cure verification.

  • Experience with robotic application equipment and/or automated paint lines.

  • Exposure to Lean, Six Sigma, PFMEA, control plans, and CI projects in a manufacturing environment.


What We Offer

  • Competitive salary and performance-based bonus opportunity.

  • Comprehensive benefits package ([health/dental/vision/401(k)/etc.]).

  • Paid time off and holidays.

  • Opportunities for growth into senior process engineering, project engineering, or leadership roles.

  • A visible impact: you’ll see your process changes show up directly as better quality, less scrap, and smoother production.