Thermal Spray Process Engineer

IBC Materials & Technologies; Lebanon (IN); On-site; USD 80,000 - 100,000; Full time

Benefits offered by this job

401(k)

401(k) matching

Dental insurance

Health insurance

Paid time off

Job summary

IBC Materials & Technologies is looking for a Thermal Spray Process Engineer to enhance our thermal spray coating operations in Lebanon, Indiana. The ideal candidate will bring their expertise in HVOF, Plasma Spray, Flame Spray, and Twin-Wire Arc Spray systems to develop new processes and support production.

This role is key in leading customer-focused technical projects, ensuring compliance with quality standards, and driving continuous improvement. Candidates must be U.S. Citizens or Green Card holders and possess a Bachelor's degree in a relevant engineering discipline.

Qualifications

• Minimum of 5 years of engineering experience in thermal spray or related coating technologies.
• Experience operating, troubleshooting, and optimizing industrial thermal spray equipment is strongly preferred.
• Must have excellent organizational and project management skills.

Responsibilities

• Develop and optimize thermal spray coating processes for production.
• Lead technical projects focused on industrial parts repair.
• Serve as the primary technical resource for customers regarding coating selection.

Skills

HVOF

Plasma Spray

Flame Spray

Twin-Wire Arc Spray

Problem Solving

Organizational Skills

Communication Skills

Education

Bachelor’s degree in Materials Engineering

Tools

Solidworks

Microsoft Office

Job description

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—including pre‑machining, surface prep, thermal spray application, and final post‑machining operations such as precision grinding. The 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 a 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, Plasma Spray, Flame Spray, and Twin‑Wire Arc Spray systems.
• Project Leadership & Parts Repair: lead comprehensive technical projects focused on industrial parts repair, managing the full sequence of operational steps including pre‑machining, thermal spray coating, and post‑coating grinding.
• Troubleshooting: address 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.
• Production Support: support production teams with process parameters, work instructions, operator training, and process controls in a hands‑on manner.
• 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: conduct 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 the supervisor.

Job Requirements

• Citizenship: Must be a U.S. Citizen or Green Card holder; sponsorship is not provided.
• Education: Bachelor’s degree in Materials Engineering, Metallurgical Engineering, Mechanical Engineering, Manufacturing Engineering, or a related engineering discipline is required.
• Experience: Minimum of 5 years of engineering experience in thermal spray or related coating technologies.
• 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 critical 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.