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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