Thermal Spray Process Engineer

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 modelling 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 the client is conditional upon results from a background check and drug test