Sr. OLED Micro-Display Process Engineer

Kopin Corporation; Westborough (MA); On-site; USD 165,000 - 195,000; Full time

Job summary

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

You will own emissive stack engineering, participate in DOE, drive transfer to high-volume manufacturing, mentor junior engineers, and collaborate with product teams and customers to meet performance and reliability targets.

Qualifications

• Bachelor’s degree in a related field required; graduate degree preferred.
• 5+ years in OLED or flat‑panel display processing, with DOE experience.
• Experience with vacuum thermal deposition, encapsulation, and cleanroom tech.

Responsibilities

• Design, develop, and optimize OLED deposition processes (VTE, sputtering, ALD).
• Own emissive stack engineering and encapsulation for micro-displays.
• Execute DOE to optimize thickness, dopants, and processing conditions.
• Lead transfer of lab processes to high-volume manufacturing and write specs.

Skills

OLED device physics

Statistical tools

Thin-film encapsulation

CMOS backplane integration

Education

B.S. in Chemical Eng / Materials / ECE / Physics

M.S. or Ph.D. strongly preferred

Tools

VTE systems

Shadow masking

EL measurement tools (XPS, SEM/TEM)

Job description

The Sr. OLED Micro-Display Process Engineer will 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 Aff 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.