Senior Controls Engineer

Position Summary Forge Nano is seeking an experienced Senior Controls Engineer to join our Engineering Design and Manufacturing Team. Reporting to the Director of Engineering, this role will provide technical leadership for automation systems, controls architecture, software standards, and safety systems supporting semiconductor ALD production equipment. The Senior Controls Engineer will lead the development and implementation of automation solutions across multiple product lines, drive controls software and architecture standards, and mentor junior engineers. This position requires extensive experience in industrial automation, PLC programming, equipment commissioning, and cross-functional collaboration to deliver reliable, scalable, and safe manufacturing equipment. The ideal candidate combines deep technical expertise with strong leadership skills and the ability to drive innovative, scalable, and reliable automation solutions that support Forge Nano's continued growth and manufacturing excellence. Responsibilities Controls Architecture & Software Development - Lead the design, development, debugging, testing, and release of PLC logic using IEC 61131-3 approved programming languages, primarily Beckhoff TwinCAT Structured Text. - Define controls architecture, software standards, reusable code modules, and automation frameworks across semiconductor ALD production equipment platforms. - Develop and implement scalable automation solutions that support product reliability, maintainability, and future expansion. - Drive software architecture decisions and establish best practices for controls programming and system integration. System Design & Safety Leadership - Lead design reviews for control narratives, safety interlocks, alarm management strategies, HMIs, database interfaces, and equipment automation schemes. - Develop and oversee HAZOP-driven safety controls logic and risk mitigation strategies. - Ensure control systems comply with applicable industry standards, including SEMI S2, SEMI E-95, ISA-101, ISA-88, and IEC 61131-3. - Partner with electrical, mechanical, process, service, and R&D teams to deliver robust and safe equipment automation solutions. Leadership & Technical Mentorship - Provide technical leadership across multiple automation projects and product lines. - Mentor and develop Controls Engineers I-III through technical coaching, design reviews, and problem-solving support. - Guide engineering teams through complex automation challenges, commissioning activities, and software feature development. - Promote engineering excellence through documentation standards, software quality processes, and continuous improvement initiatives. Commissioning, Support & Continuous Improvement - Lead equipment commissioning, start-up, troubleshooting, validation, and field support activities for critical automated systems. - Support customer installations and resolve complex controls-related issues in manufacturing and field environments. - Drive best practices for version control, software validation, release management, testing, and lifecycle documentation. - Collaborate with service and manufacturing teams to improve system performance, reliability, and maintainability. Qualifications Required Qualifications - Bachelor's degree in Electrical Engineering, Controls Engineering, Automation Engineering, Computer Engineering, or a related technical discipline. - Minimum of 7 years of experience in controls programming, industrial automation, equipment automation, or related engineering roles. - Advanced experience with Beckhoff TwinCAT Structured Text programming. - Demonstrated expertise designing and architecting controls systems across multiple equipment platforms or product lines. - Experience leading HAZOP-based safety controls design and implementation. - Strong technical writing, communication, leadership, and mentoring ski ls. - Proven ability to collaborate effectively across cross-functional engineering and operations teams. Preferred Qualifications - Experience with Ignition, Allen-Bradley Studio 5000, Python, OPC-UA, SQL databases, and historian systems. - Experience supporting semiconductor manufacturing equipment or advanced process automation systems. - Knowledge of software version control systems, validation protocols, and automated testing practices. - Familiarity with SEMI S2, SEMI E-95, ISA-101, ISA-88, and related automation standards. - Previous experience providing technical leadership or supervising engineering teams. Work Environment This position is based on-site and requires regular interaction with manufacturing, engineering, laboratory, and production environments. Employees are required to wear appropriate personal protective equipment (PPE), including but not limited to safety glasses, gloves, steel-toed shoes, lab coats, and hard hats when working in designated production areas. Strict adherence to company safety policies and operating procedures is required. Forge Nano maintains all required workplace health and safety protocols and expects employees to comply with established guidelines. Physical Requirements The physical demands described here are representative of those necessary to successfully perform the essential functions of this position. Reasonable accommodations may be made for qualified individuals with disabilities. The role frequently requires standing, walking, reaching, using hands for handling equipment and controls, and communicating with team members. Employees may occasionally work near moving mechanical equipment and in moderate noise environments. Travel Occasional travel of up to 15% may be required to support customer installations, equipment start-up activities, commissioning efforts, and maintenance support at client locations. Compensation & Benefits Salary Range: $115,000.00 - $135,000.00 annually, depending on experience, qualifications, and internal equity. Benefits Offered: - Medical, Dental, and Vision Insurance - Life and Disability Insurance - Short-Term and Long-Term Disability Coverage - Flexible Spending Account (FSA) and Health Savings Account (HSA) Options - 401(k) Retirement Plan with Company Match - Paid Time Off (PTO) - Paid Holidays - Paid Parental Leave Forge Nano Inc. is proud to be an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, veteran status, or any other protected status under applicable law. In compliance with federal law, all persons hired will be required to verify identity and eligibility to work in the United States and complete the required employment eligibility verification documentation upon hire.