About this opportunity
Ensurge Inc. lists this Senior Manufacturing Engineer – Thin Film Engineering (PVD, PECVD, ALD & RIE) opportunity in san jose, California. Review the employer’s description below for duties, qualifications and application requirements.
Job description
About Ensurge Micropower
Ensurge Micropower (OSE: ENSU) is a pioneer in solid-state microbattery technology, enabling the next generation of intelligent, connected devices. Leveraging proprietary thin-film and roll-to-roll manufacturing, Ensurge delivers safe, high-energy-density batteries for wearables, health tech, industrial sensing, and defense applications. As our technology transitions from development to production, disciplined manufacturing execution becomes the differentiator.
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 to deposition/etch to 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, and 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 (standardwork, DMS, etc.)
Qualifications
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 → 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
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.
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Worksite address
san jose, CA, 95199, US
Who can apply
Review the original listing for work authorization, qualifications and employer requirements.