Thermal Spray Process Engineer

IBC MATERIALS & TECHNOLOGIES, LLC; Lebanon (IN); On-site; USD 90,000 - 120,000; Full time

Benefits offered by this job

401(k)

401(k) matching

Dental insurance

Health insurance

Paid time off

Job summary

IBC Group is seeking an experienced Thermal Spray Process Engineer in Indiana to support and advance coating operations. You will manage process development, production support, and documentation for HVOF, Plasma Spray, Flame Spray, and Twin-Wire Arc Spray systems, coordinating pre-machining through post-machining steps to ensure coating performance.

The role calls for hands-on expertise, project leadership, and collaboration with production, customers, and leadership to drive quality,

Qualifications

• Bachelor’s degree in an engineering discipline related to materials/coatings.
• Minimum 5 years of engineering experience in thermal spray or coatings technologies.
• Hands-on experience with HVOF, Plasma Spray, Flame Spray, and Twin-Wire Arc Spray operations.
• Experience operating, troubleshooting, and optimizing industrial thermal spray equipment.
• Strong knowledge of coating properties, metallurgy, surface prep, masking, and finishing tolerances.
• Proficient with SolidWorks or equivalent 3-D modeling software.

Responsibilities

• Develop, optimize, and maintain thermal spray coating processes for production and new applications.
• Provide technical expertise for HVOF, Plasma Spray, Flame Spray, and Twin-Wire Arc Spray systems.
• Lead projects focused on industrial parts repair and end-to-end process execution.
• Troubleshoot coating, equipment, and process issues to improve quality and throughput.
• Read, interpret, and create blueprints and technical reports.

Skills

HVOF

Plasma Spray

Flame Spray

Twin-Wire Arc Spray

SolidWorks

Project leadership

Troubleshooting

Metallurgical analysis

Quality standards

Microsoft Office

Education

Bachelor’s degree in Materials/Metallurgical/Mechanical/Manufacturing Engineering

Tools

SolidWorks

Job description

About The Company

IBC Group is an industrial solutions provider specializing in advanced metal coatings, component repair, and performance engineering. We partner with manufacturers to extend the life of critical equipment, improve performance, and solve challenges related to wear, corrosion, and durability. Our capabilities include a wide range of thermal spray and performance coating technologies, supported by metallurgical expertise to ensure solutions meet demanding specifications. From restoring worn components to enhancing new parts, our work helps customers reduce downtime and improve reliability across a variety of industries. IBC Group operates focused on leveraging advanced surface engineering solutions globally.

Benefits

• 401(k)
• 401(k) matching
• Dental insurance
• Health insurance
• Paid time off

About The Company

IBC Group is an industrial solutions provider specializing in advanced metal coatings, component repair, and performance engineering. We partner with manufacturers to extend the life of critical equipment, improve performance, and solve challenges related to wear, corrosion, and durability. Our capabilities include a wide range of thermal spray and performance coating technologies, supported by metallurgical expertise to ensure solutions meet demanding specifications. From restoring worn components to enhancing new parts, our work helps customers reduce downtime and improve reliability across a variety of industries. IBC Group operates focused on leveraging advanced surface engineering solutions globally.

IBC Group is an equal opportunity employer. Full-time employees qualify for additional benefits like medical, vision, and dental insurance, paid time off (i.e. vacation), and retirement savings options.

Position Summary

We are seeking an experienced Thermal Spray Process Engineer to support and improve thermal spray coating operations in a manufacturing environment. This position is responsible for process development, production support, process documentation, quality improvement, troubleshooting, customer support, and continuous improvement initiatives related to thermal spray technologies. The ideal candidate will have strong hands-on and technical experience with multiple thermal spray processes, including HVOF, Plasma Spray, Flame Spray, and Twin-Wire Arc Spray systems. Crucially, this individual must possess the ability to lead end-to-end technical projects related to component parts repair—orchestrating everything from pre-machining and surface prep to thermal spray application and final post-machining operations (including precision grinding). This role works closely with production, customers, and leadership to ensure coating performance, operational efficiency, and compliance with customer and industry requirements. Due to ITAR and customer compliance requirements, candidates must be either a U.S. Citizen or U.S. Permanent Resident (Green Card Holder).

Essential Duties And Responsibilities

• Process Development: Develop, optimize, and maintain thermal spray coating processes for production and new customer applications.
• Technical Expertise: Provide core technical expertise for HVOF (High Velocity Oxygen Fuel), Plasma Spray, Flame Spray, and Twin-Wire Arc Spray systems.
• Project Leadership & Parts Repair: Lead comprehensive technical projects focused on industrial parts repair, successfully managing the full sequence of operational steps including necessary pre-machining, thermal spray coating, and precision post-machining/grinding.
• Troubleshooting: Troubleshoot coating, equipment, and process issues to improve quality, repeatability, and throughput.
• Contract Review: Perform daily contract review on incoming jobs, creating precise process instructions in the ERP system for production staff to follow.
• Production Support: Support production teams with process parameters, work instructions, operator training, and process controls, taking a primarily hands-on approach.
• Tooling & Design: Design fixturing and masking for customer parts as needed.
• Technical Documentation: Read, interpret, and create blueprints, technical drawings, schematics, and computer-generated reports.
• Metallurgical Analysis: Perform coating evaluations, root cause investigations, and metallurgical analysis to identify process improvements and resolve customer issues.
• Capital Improvements: Assist with equipment evaluations, maintenance coordination, and capital improvement projects.
• Customer Interface: Serve as the primary technical resource for customers regarding coating selection, process capabilities, feasibility assessments, and root-cause investigations.
• Quality Compliance: Follow all AS9100/ISO 9001 standards, internal quality policies, OSHA safety regulations, and company safety policies.
• General Assignments: Complete additional assignments and projects as prescribed by your supervisor.

Job Requirements

• Citizenship: Must be a U.S. Citizen/Green Card holder. Sponsorship is not provided for this position.
• Education: Bachelor’s degree in Materials Engineering, Metallurgical Engineering, Mechanical Engineering, Manufacturing Engineering, or a related engineering discipline is required.
• Experience: A minimum of 5 years of engineering experience in thermal spray or related coatings technologies is required.
• Technology Competency: Demonstrated hands-on experience with HVOF, Plasma Spray, Flame Spray, and Twin-Wire Arc Spray operations.
• Equipment Know-How: Experience operating, troubleshooting, and optimizing industrial thermal spray equipment is strongly preferred.
• Manufacturing Process Depth: Strong understanding of coating properties, metallurgy, surface preparation, masking, and crucial finishing operations (including pre- and post-coat machining and grinding tolerances).
• Problem Solving: Proven experience troubleshooting thermal spray processes and complex coating quality issues.
• Software: Solidworks or equivalent 3-D modeling software experience is required.
• Leadership & Communication: Strong communication skills with a proven ability to train operators, lead technical projects cross-functionally, and collaborate across departments.
• Organization: Must have excellent organizational and project management skills.
• Software Proficiency: Must be proficient in Microsoft Office software.
• Physical Demands: Ability to work in a manufacturing environment with exposure to noise, heat, dust, and industrial equipment. Ability to stand, walk, bend, and lift up to 50 pounds occasionally.
• PPE: Ability to wear required PPE, including respirators, eye, and hearing protection when necessary.
• Screening: All employment at IBC Group is conditional upon results from a background check and drug test.