Coating Engineer

AM Global; Leicester Forest East; On-site; GBP 65,000 - 90,000; Full time

Job summary

AM Global is seeking a highly skilled Thin Film Coating Engineer to oversee development, scaling and production of advanced thin film coatings. You will design coating stacks, optimize deposition equipment and troubleshoot process variation to meet specifications, collaborating with R&D and manufacturing to transition designs from concept to high-volume production.

You will lead quality assurance, process control and continuous improvement efforts, applying Lean/Kaizen to reduce defects, improve

Qualifications

• Experience designing coating stacks and optimizing deposition processes.
• Strong knowledge of ISO 9001 and quality systems.
• Experience with DOE and process capability (Cpk≥1.33).
• Experience in high-volume manufacturing.

Responsibilities

• Design coating stacks and simulate thin film performance using specialized software.
• Develop deposition recipes for PVD/CVD to achieve target thickness and properties.
• Lead quality assurance and process control initiatives across production lines.
• Scale pilot processes to high-volume manufacturing with stable processes.
• Lead quality audits and CAPA activities to maintain standards.

Skills

SPC charts

CTQ parameters

Lean manufacturing

Quality systems

Quality audits

Cross-functional teamwork

Education

Bachelor's/Master's/PhD in Materials Science, Physics or Chemical Engineering

Tools

Essential Macleod

TFCalc

OptiLayer

DOE software

Job description

SUMMARY OF JOB RESPONSIBILITIES:

We are seeking a highly skilled Thin Film Coating Engineer to oversee the development, scaling, and production of advanced thin film coatings. In this role, you will design coating stacks, optimize deposition equipment, and troubleshoot process variations to meet strict optical, electrical, or mechanical specifications. You will collaborate closely with R&D and manufacturing teams to transition new coating designs from concept to high-volume production.

Continuous Improvement Drive change through continuous improvement, including by setting goals and measuring and communicating our performance accordingly.

DUTIES AND RESPONSIBILITIES:

Quality Assurance & Process Control

• Establish Statistical Process Control (SPC): Define, monitor, and maintain SPC charts for critical-to-quality (CTQ) coating parameters (e.g., thickness uniformity, refractive index, adhesion) to identify and correct process drift before defects occur.
• Define Quality Standards: Draft, implement, and update incoming raw material specifications, in-process inspection criteria, and final product release standards for all coated substrates.
• Lead Continuous Improvement: Apply, Lean, or Kaizen methodologies to systematically reduce coating defects (like pinholes, flaking, or contamination), improve yields, and lower the Cost of Poor Quality (COPQ).
• Manage Non-Conformance (MRB): Support the Quality engineer with the Material Review Board (MRB) process for the coating department. Issue, investigate, and close out Corrective and Preventive Actions (CAPA) using structured problem-solving (e.g., 8D, 5-Why, Fishbone diagrams).
• Audit & Compliance: Ensure the coating line remains fully compliant with internal quality systems and external industry standards (e.g., ISO 9001). Act as the technical subject matter expert during quality audits.

Process Development & Optimization

• Design coating stacks and simulate thin film performance using software (e.g., Essential Macleod, TFCalc, or OptiLayer).
• Develop deposition recipes for techniques such as PVD (sputtering, e-beam evaporation) or CVD to achieve target thickness, uniformity, and material properties.
• Execute Design of Experiments (DOE): Plan and run structured DOEs to validate process windows, optimize parameters (vacuum levels, gas flows, temperature), and ensure process capability (\(C_{pk} \ge 1.33\)).

Quality Testing, Metrology & Characterization

• Qualify Metrology Equipment: Support the Manufacturing cell, with the calibration, Gauge R&R (Repeatability and Reproducibility) studies, and preventative maintenance of all thin-film characterization tools.
• Analyze Coating Integrity: Utilize spectrophotometers, to verify coating quality against customer drawings.
• Execute Reliability Testing: Design and oversee accelerated environmental stress testing, including thermal cycling, humidity exposure, salt spray, and mechanical adhesion testing (e.g., tape pull, nanoindentation).

Equipment & Operations

• Manage deposition equipment, ensuring regular calibration, support the implementation of effective preventive maintenance, and troubleshooting of vacuum systems.
• Scale up processes from pilot scale to high-volume manufacturing lines while maintaining process stability.
• Write standard operating procedures (SOPs) and train technicians on safe tool operation and in-line quality inspections.

People Management

• Lead and/or support groups of technicians and engineers
• Provide guidance to other team members
• Train both team and broader organisation members

Relationship Management

• Support regular coating productivity meetings with representatives from appropriate departments to establish an action plan for improving build quality
• Communicate efficiently throughout the shop floor and with own and customer's management
• Liaise and communicate with other departments, customers, suppliers and other service providers

Self Management

• Comply with the Health, Safety and Environmental Policies
• Assertive, resilient and welcomes change
• Engages interest and participation of others and has a collaborative approach to working with others
• Proactively contributes to the team
• Is self aware
• Is resilient, optimistic and open to change
• Shows moral courage, openness and honesty in all dealings

SKILLS AND REQUIRED ABILITIES:

• Exercise substantial initiative/judgement in work methods and interpreting goals
• Work independently and is reviewed infrequently with minimal supervision
• Self-supervising within the guidance and expectations of divisional management
• Knowledge of quality systems and measurement
• Lean Manufacturing knowledge
• Understanding of ISO14001 and Health and Safety practices
• Understanding of engineering drawings and manufacturing processes
• Ability to work in a diverse and dynamic environment
• Planning and prioritising activities
• Good communication and interpersonal skills
• Negotiation skills
• Ability to present data effectively
• Problem-solving skills
• Team working skills
• Analytical skills
• Understanding of cost and financial impacts

EDUCATION AND EXPERIENCE:

• Degree requirement: Bachelor's, Master's, or Ph.D. in Materials Science, Physics, Chemical Engineering, or a related STEM field.
• Experience: 5+ years of hands‑on experience operating industrial vacuum deposition systems, with a proven track record of managing manufacturing quality systems.
• Membership of an industry related Professional Body would be advantageous
• Previous experience in a high volume manufacturing environment
• Experience of dealing with customers and suppliers Example roles this job description may cover