Thin Film Coating Engineer

AM Global; Leicester; On-site; GBP 40,000 - 65,000; Full time

Job summary

AM Global in the United Kingdom seeks a Thin Film Coating Engineer to design coating stacks, optimize deposition equipment, and scale processes from pilot to high-volume production.

You will drive quality systems (SPC, CTQ), develop DOE studies, and collaborate with R&D and manufacturing to meet strict optical/electrical specs while ensuring safety and compliance.

Qualifications

• Experience in coating development and QA of thin films.
• Knowledge of coating standards and process control.
• Ability to lead continuous improvement in manufacturing.

Responsibilities

• Establish SPC charts for CTQ coating parameters.
• Define and maintain material specs and in-process inspection criteria.
• Lead continuous improvement to reduce defects and COPQ.
• Support MRB, CAPA actions using 8D or 5-Why methods.
• Audit compliance with ISO 9001 and internal quality systems.
• Scale coating processes from pilot to high-volume production.
• Write SOPs and train technicians.
• Collaborate with R&D and manufacturing to transition designs.

Skills

SPC (Statistical Process Control)

Quality assurance

Lean / Kaizen methodologies

DOE (Design of Experiments)

MRB / CAPA processes

ISO 9001 compliance

PVD/CVD deposition knowledge

Sputtering / e-beam evaporation

Metrology & instrumentation

Statistical data analysis

Tools

Essential Macleod

TFCalc

OptiLayer

Job description

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 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
• Ability to present data effectively
• Problem-solving skills
• Team working skills
• Analytical skills
• Understanding of cost and financial impacts