Role Overview
Ensurge is seeking a Senior Manufacturing Engineer (IC) to own and scale the Thin-Film
Engineering processes - deposition (PVD/Sputtering, PECVD, ALD) and etch (RIE) - from
pilot through early production. This role is not just about process - it is about delivering
manufacturing results.
Responsibilities
Own daily manufacturing performance for the PVD/Sputtering, PECVD, ALD, and RIE
process areas
- Drive output, yield, uptime, and cycle time
- Support production directly - troubleshooting issues in real time
- Partner with Operations to ensure line execution meets plan
Convert R&D processes into repeatable, production-ready workflows
- Define and lock critical process parameters (CPPs) - e.g., chamber pressure, Ar/process
gas flow, RF/DC power, substrate bias, deposition rate, film stress and thickness
uniformity targets (PVD/PECVD); precursor/co-reactant pulse and purge times, cycle
count, growth per cycle (GPC), and substrate temperature (ALD); RF power, gas
chemistry (e.g., CF4/O2/Cl2), etch rate, selectivity, sidewall profile/anisotropy, DC bias,
and endpoint detection (RIE) - Define and lock control limits and OCAPs
- Ensure processes are robust, stable, and scalable
Work with Equipment Engineering to: - Define tool requirements (sputter cathodes/targets, PECVD chambers, ALD reactors and
precursor delivery systems, RIE/ICP-RIE chambers and endpoint detection systems,
RF/DC power supplies, vacuum, gas delivery, and abatement/scrubber systems) - Improve reliability and uptime
- Implement process-driven upgrades
- Lead tool qualification and process acceptance
- Ensure equipment supports throughput, precision, and repeatability
Own flow from substrate input 1 deposition/etch 1 downstream handoff to assembly - Reduce bottlenecks, WIP, and inefficiencies
- Improve line balance and production scheduling alignment
- Support layout and flow improvements as the system scales
Partner with Quality to implement: - SPC and process control on film thickness, stress, uniformity, and conformality
- Film characterization (ellipsometry, profilometry, XRD, SEM/AFM, four-point probe) to validate deposition results against CPPs
- Traceability and data capture
Build and maintain: - SOPs
- Process specs
- Control plans
- Ensure manufacturing is data-driven and auditable
Lead structured RCA on: - Yield loss
- Defects
- Downtime
- Use characterization data (SEM, XRD, cross-section imaging) to root-cause excursions
- Implement sustainable fixes - not workarounds
- Drive continuous improvement aligned to operational excellence principles (standard work, DMS, etc.)
Qualifications
Required - 7-12+ years in manufacturing engineering with thin-film deposition and etch
(PVD/sputtering, PECVD, ALD, and/or RIE) in battery, semiconductor, or thin-film
industries - Proven experience owning manufacturing processes on the floor
- Strong track record of driving yield and throughput improvements
- Experience supporting or leading pilot 1 production scale-up
- Hands-on mindset - comfortable working directly with equipment, technicians, and
operators - Working knowledge of thin-film characterization techniques (e.g., ellipsometry,
profilometry, XRD, SEM) and their use in validating and controlling deposition processes
Preferred - Understanding of film stress engineering, plasma physics, RF coupling, and DC self-bias
- Understanding of plasma etch chemistry, selectivity, anisotropy, and endpoint detection
(RIE/ICP-RIE) - Familiarity with ALD precursor chemistry, self-limiting surface reactions, and pulse/purge sequencing
- Vacuum systems and chamber conditioning experience
- Experience with image-based film/defect characterization (SEM, optical microscopy) and
correlating characterization data back to process control limits - Experience with MES, traceability systems, or data-driven manufacturing
Salary Range:
$162,000-$198,000
The base salary range is specific to California. The salary of the final candidate selected for this role will be determined by a variety of factors, including, but not limited to, internal equity, experience, education, specialty, and training.
