Director of Process Engineering
Director of Process Engineering
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Job Description
Discover
The Opportunity
Do you have a passion for transforming cutting-edge lab inventions into rock-solid manufacturing processes Do you thrive on optimizing complex workflows until they hum at peak efficiency Join Rayleigh Solar Tech as the Director of Process Engineering and lead the team that will turn our innovative perovskite solar cell designs into a finely tuned roll-to-roll production operation.
At Rayleigh were building the lowest-cost source of clean electrons on the planet. Backed by world-class investors and a powerhouse technical team we push the limits of deep tech to make solar radically more accessible. Our culture thrives on curiosity urgency and the pursuit of excellence - and were looking for someone who shares that fire.
If youre a process engineering expert with a strategic mindset an obsession for quality (you dream in CpK and sigma levels) and a drive to scale breakthroughs into world-changing products we want to work with you.
What youll do
Responsibilities
What Youll Do
In this role youll spearhead the development and optimization of every step in our fabrication process - from initial coating trials through full-scale module assembly. Youll establish robust high-yield processes by experimenting analyzing data and refining techniques to achieve unprecedented consistency and quality. Whether its improving layer uniformity or increasing throughput implementing real-time controls or reducing variability youll ensure that our manufacturing is not only fast but flawlessly reproducible. Your work will directly enable us to deliver cutting-edge solar technology at industrial scale.
Lead the Scale-Up:
- Own the end-to-end development of sheet-to-sheet and roll-to-roll fabrication processes for Rayleighs perovskite solar modules. Youll take lab-scale methods and relentlessly improve and iterate on them until theyre ready for high-throughput manufacturing - bridging the gap from lab to fab
Optimize Every Input/Output:
- Refine coating drying annealing and encapsulation processes to maximize yield uniformity and device performance. This means mastering countless parameters (coating speeds injection rates temperatures etc.) and environmental conditions to achieve consistent film and product quality at scale. Youll conduct design-of-experiments to dial in these settings and eliminate defects pushing our processes toward six-sigma levels of control.
Data-Driven Control
- Implement robust statistical process control (SPC) and real-time monitoring across the production line. From inline sensors to automated data dashboards youll ensure we measure what matters. When a process drifts or a metric starts to slip your team catches it early and corrects course using data. Over time youll build AI/ML models to help predict and improve process outcomes as well.
Pioneer New Techniques:
- Stay on the cutting edge of manufacturing science. Evaluate and introduce advanced techniques and equipment - whether its a novel deposition method in-situ characterization tool or an AI-driven control algorithm - to continually improve efficiency and consistency. Youre not afraid to question traditional methods if a new approach could yield better results.
Cross-Functional Collaboration:
- Work hand-in-hand with the Equipment Engineering Director to ensure our processes and machines are in perfect harmony. If a process needs a custom equipment tweak youll specify it; if a tool has certain capabilities youll exploit them fully in the process. Youll also interface with the R&D (materials/science) team to translate material breakthroughs into scalable process recipes and with the quality/reliability team to bake in robustness from the start.
Mentor and Grow the Team:
- Build and lead a high-performing process engineering team. Youll set clear objectives empower engineers to run experiments and share ideas and cultivate a culture of continuous improvement. By mentoring junior members and promoting knowledge sharing you ensure the whole team grows into world-class experts on perovskite manufacturing.
What youll need
Qualifications
What You Bring
Education & Experience:
- . or Ph.D. in Chemical Engineering Materials Science Mechanical Engineering or a related field. 10 years of experience in process development and scale-up for advanced manufacturing. Youve likely worked in industries like photovoltaics semiconductors or advanced materials where you took a new product or technology from prototype into full production.
Thin-Film Process Mastery:
- Deep expertise in thin-film deposition and printing techniques relevant to perovskite solar cells - for example solution processing (slot-die coating inkjet printing) vacuum deposition sintering/annealing processes laser patterning and lamination. You understand how to optimize these processes for both performance and manufacturability.
Quality & Statistical Savvy:
- Strong foundation in statistical process control Six Sigma and design of experiments (DOE). Youve set up control charts conducted DOEs to find optimal conditions and are comfortable using tools like JMP Minitab or Python for data analysis. Variation is your enemy and data is your weapon to defeat it.
Scale-Up Achievements
- A proven track record of scaling a process from lab to production. Perhaps you helped ramp a new production line or transferred a process to a contract manufacturer or overcame a major scaling challenge (like maintaining uniformity when moving from small substrates to large rolls). You know the common pitfalls when scaling (edge effects environmental sensitivity etc.) and how to address them.
Problem-Solving and Innovation:
- Youre a creative engineer who can figure out why a process isnt working and how to improve it. Whether its using a novel solvent mix to eliminate a coating defect or tweaking a process sequence to boost adhesion between layers you innovate to solve problems. And you document everything so the solution becomes part of standard practice.
Leadership & Communication:
- Experience building or managing a team of engineers or scientists. You excel at breaking down big goals into manageable projects delegating tasks and guiding your team through complex development cycles. You communicate progress and challenges upward in a clear honest way. When speaking with other teams or executives you can translate technical process metrics into implications for product performance or timeline.
Passion for the Mission:
- Above all youre motivated by the impact of bringing low-cost clean energy to the world. The idea of leading the commercialization of a breakthrough solar technology excites you. Youre willing to pour your expertise and heart into this challenge because you know how high the stakes are for our company and the planet.
A little bit about us
Rayleigh Solar Tech
Here at Rayleigh were commercializing the next generation of solar technology: flexible perovskite solar panels. Our company is united by our commitment to change the planet for the better. We push the boundaries of whats possible our passion for deep tech to solve hard engineering problems our insatiable curiosity that forces us to ask questions and our relentless drive for excellence in everything we touch.
Are you interested
Work With Us
Why Rayleigh
Were not just building solar tech-were building a movement. A world where clean energy isnt a luxury but a given. At Rayleigh youll find a mission you can believe in a team that will push you to be your best and a culture that celebrates bold ideas deep science and meaningful impact.
Diversity and Inclusion
At Rayleigh we know that diversity makes a strong team. We encourage all qualified applicants to apply for this position and we will never discriminate against race ethnicity gender identity gender expression sexual orientation disability religion marital status or family status. Instead we work to celebrate the things that make us unique and create an inclusive environment for all employees.
Dont meet all the requirements outlined above but still find yourself excited about this position and Rayleighs mission If you believe that you have the skills and experience to excel in this role we would love to see your application!
Required Experience:
Director
Employment Type
Full-Time
