Process Engineer

Job Description

Job Description

Process Development Engineer – Solar

Summary

The Process Development Engineer is responsible for developing, implementing, and optimizing thin-film coating processes to support stable, high-volume production of photovoltaic (solar) modules.

Reporting Structure

Reports to: VP, Manufacturing

Location

Rochester, NY area

Key Responsibilities

Product R&D

• Design and execute experiments to develop and improve materials and manufacturing processes for enhanced product performance
• Conduct lab and pilot-scale testing; analyze results and recommend next steps
• Monitor product and process performance throughout development cycles
• Evaluate data and identify continuous improvement opportunities
• Perform material characterization using tools such as SEM, AFM, XRF, and profilometry
• Support implementation of in-line metrology tools to ensure coating quality and consistency

Manufacturing Development

• Optimize processes for high-volume, stable production environments
• Develop and maintain process documentation and SOPs
• Define equipment requirements and assist with vendor selection
• Support production cost estimation and process efficiency improvements
• Ensure compliance with environmental, health, and safety regulations
• Assist with production line layout and scale-up activities

Required Qualifications

• Experience developing thin-film products and manufacturing processes
• Knowledge of roll-to-roll processing (unwinding/winding, splicing, coating, laminating, web handling)
• Exposure to manufacturing or production environments
• Experience with at least one of the following:
  • Gravure coating
  • Slot die coating
  • Flexographic printing
  • Laser patterning

Preferred Qualifications

• Experience with thin-film solar technologies (e.g., perovskite solar cells)
• Ink formulation experience
• Design of Experiments (DOE)
• Vacuum deposition or atomic layer deposition
• Lean manufacturing knowledge
• Project management experience

Education & Experience

• Bachelor’s degree in Engineering, Science, or related technical field (advanced degree preferred)
• Experience supporting production environments
• Experience with process or product scale-up

Core Competencies

• Strong technical and analytical problem-solving skills
• Ability to collaborate across teams and with external partners
• Familiarity with process simulation tools and standard operating procedures
• Experience with CAD/AutoCAD preferred
• Understanding of health and safety regulations

Physical Requirements

• Ability to bend, twist, push, and pull as needed
• Ability to lift up to 40 lbs

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