Senior OLED Micro-Display Process Engineer

Kopin Corporation; Westborough, Northern (MA, KY); Hybrid; USD 165,000 - 195,000; Full time

Job summary

Kopin Corporation in Westborough, MA, seeks a Senior OLED Micro-Display Process Engineer to lead development, optimization, and manufacturing of high‑resolution micro-displays for AR/VR, medical imaging, and defense.

You will own deposition and encapsulation processes, run DOE studies, mentor junior engineers, and drive process integration from lab to high‑volume manufacturing, delivering reliable performance and scalable yield.

Qualifications

• OLED deposition processes including thermal evaporation, sputtering and ALD.
• Emissive stack engineering (HIL, HTL, EML, ETL, EIL), cathode deposition, and thin-film encapsulation (TFE).
• DOE to optimize thickness, doping profiles, and processing for luminance, color purity, and lifetime.
• Process integration across OLED stack and backplane to meet electrical/optical targets.

Responsibilities

• Perform advanced thin-film metrology (ellipsometry, XRD, XPS, SIMS, SEM/TEM, AFM).
• Device-level characterization: EL spectra, J-V-L curves, angular emission, color gamut, lifetime testing.
• Lead structured RCA and 8D corrective actions for yield and reliability.
• Manage process FMEA and monitor CPK metrics for critical steps.

Skills

OLED device physics

Statistics/DOE analysis

Backplane integration knowledge

Problem solving

Education

B.S. in Chemical Engineering, Materials Science, Electrical Engineering, Physics, or related

MS or PhD strongly preferred

Tools

VTE systems

Shadow masking

ALD/CVD thin-film deposition

Job description

POSITION: Senior OLED Micro-Display Process Engineer
REPORTING TO: VP of Engineering
LOCATION: Westborough, MA.

GENERAL FUNCTION:

Lead the development, optimization, and manufacturing of high-resolution micro-display products targeting AR/VR, medical imaging, defense, and consumer electronics applications.

KEY DUTIES AND RESPONSIBILITIES:

Process Development & Optimization

• Design, develop, and optimize OLED thin-film deposition processes including thermal evaporation, sputtering and ALD processes.
• Own process modules for emissive stack engineering (HIL, HTL, EML, ETL, EIL), cathode deposition, and thin-film encapsulation (TFE) for micro-displays.
• Define and execute DOE (Design of Experiments) to optimize layer thickness, doping profiles, and process conditions for target luminance, color purity and lifetime.
• Lead process integration activities across OLED stack and backplane to ensure electrical and optical performance targets are met.

Characterization & Failure Analysis

• Perform and interpret advanced thin-film metrology including spectroscopic ellipsometry, XRD, XPS, SIMS, SEM/TEM cross-section, and AFM.
• Work with device test team to conduct device-level characterization: EL spectra, J-V-L curves, angular emission, color gamut, and accelerated lifetime testing.
• Lead structured root cause analysis (RCA) and 8D corrective action for yield excursions and reliability failures.
• Manage process FMEA and maintain process control plans; define and monitor CPK metrics for critical process steps.

Manufacturing Scale-Up & Yield Improvement

• Transfer lab-proven processes to high-volume manufacturing (HVM) environments; write and maintain process specifications, traveler steps, and equipment recipes.
• Drive yield improvement initiatives through SPC, APC, and statistical analysis of inline and end-of-line data.
• Evaluate and qualify new organic and inorganic materials (emitters, hosts, transport materials, encapsulants) from supply chain partners.

Cross-Functional Collaboration & Leadership

• Act as technical lead and mentor for junior and mid-level process engineers; provide guidance on experimental design, data interpretation, and problem-solving methodology.
• Interface directly with product management and customers to understand application requirements and translate them into process specifications.
• Represent the process engineering function in design reviews, technology roadmap discussions, and customer technical audits.

MINIMUM JOB REQUIREMENTS:

Education

• B.S. in Chemical Engineering, Materials Science, Electrical Engineering, Physics, or a closely related discipline required.
• M.S. or Ph.D. strongly preferred; relevant industrial experience may substitute.

Experience

• Kopin is a defense contractor and is subject to International Traffic in Arms Regulations (ITAR). You must be a US Citizen or Permanent Resident (green card holder) to be considered for this position.
• 5+ years of hands-on process engineering experience in OLED device fabrication, thin-film semiconductor processing, or flat-panel display manufacturing (3+ years with advanced degree).
• Demonstrated experience with vacuum thermal evaporation (VTE) systems, shadow masking, and organic thin-film deposition in a cleanroom environment.
• Proven track record of process development from concept through HVM transfer, including DOE execution, data analysis, and specification authorship.
• Prior experience with micro-display products (e.g., OLEDoS, LCoS, μLED) or high-PPI AMOLED display fabrication is strongly preferred.

Technical Skills

• Deep knowledge of OLED device physics: charge transport, exciton dynamics, optical microcavity design, and degradation mechanisms.
• Proficiency with statistical tools (JMP, Minitab, Python/R) for SPC, DOE analysis, and yield modeling.
• Experience with thin-film encapsulation (ALD, CVD, hybrid organic-inorganic multilayers) for moisture/oxygen barrier applications.
• Working knowledge of CMOS backplane integration requirements.

PHYSICAL REQUIREMENTS:

• Able to rotate from sitting to standing, lift up to 20 pounds, and gown according to clean room protocol.

**The salary range for this position is $165k to $195k annually, plus bonus**

Kopin Corporation is an Equal Employment Opportunity and Affimative Action employer and as such all qualified applicants will be considered for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability or veteran status, age or any other federally protected class. If an applicant needs a reasonable accommodation due to a disability with the application process, there is additional information on our website at www.kopin.com/careers .