Andrew P. Clarke

Consultant overview

Andy has developed reliable products and processes for more than thirty years — directing PVD technology strategy at Plasma-Therm, developing detector and IC integration processes at Raytheon, and founding, scaling, and selling deposition equipment companies. His work has resulted in more than 30 critical trade secrets, 19 U.S. patents, and over a dozen published papers and technology awards. His training and long experience span a range of physics-informed expertise, from plasma processing to the practical sciences of product development and lean manufacturing. He has helped clients and past employers overcome many costly manufacturing problems, often by finding and developing a simple, low-cost solution.

How Andy can help

• Vacuum process technology — process development, materials integration, and physics-based analysis of systems
• Process reliability and yield — root-cause failure analysis, yield improvement, and cycle time reduction
• Capital equipment analysis and selection — tool evaluation, acceptance, technology roadmaps, budgets, and program timelines
• Patent services — patentability analysis, including prior art research and comparison, and patent specification writing
• Expert witness engagements — experienced expert witness in trade secret disputes, and declaration writing for ex parte patent reexaminations

Getting started

A problem is costing your company money, but you and your team are too busy to focus on it — or you may feel you could benefit from a critical “outside the box” perspective. Email Andy to schedule a free 20-minute consultation. If your problem sounds like something he can help with and you would like his further help, he will provide his rates and availability. Professional references are available on request.

Engagement begins with the signing of NDAs and agreement on a scope of work and an estimate. Work starts once terms are agreed and a purchase order is received.

Selected experience

PVD Technology Director, Plasma-Therm LLC (2023–2026) Led development, market adoption, and profitability of two semiconductor equipment product lines. Defined technology roadmaps, budgets, and timelines while enhancing manufacturing efficiency and process capability. Supported global sales through technical marketing.

Senior Principal Engineer, Raytheon (2013–2023) Developed manufacturable processes for detector and IC integration, improving yield and performance through failure analysis and innovation. Mentored engineers and led cross-functional innovation efforts resulting in 11 patents and 30+ trade secrets.

Technology Consultant & Expert Witness (2006–2013) Delivered materials and equipment solutions; served as expert witness in patent and trade secret litigation.

VP & General Manager, PVD Products Division, Tegal Corporation (2004–2006) Turned a 30-person division from losses to profitability. Improved morale, retention, and aligned sales strategy with evolving markets.

Founder & CEO, First Derivative Systems, Inc. (1999–2004) Led product development, fundraising, and strategic partnerships. Secured a $100M+ joint development agreement and negotiated the successful acquisition by Tegal Corporation.

Senior VP, Sputtered Films, Inc. (1989–1999) Scaled revenue from under $1M to over $20M by leading product development, recruiting high-performing teams, and expanding engineering and marketing capabilities.

US DOE Graduate Fellow, Los Alamos National Laboratory (1987–1989) Conducted research on alloy systems and high-temperature superconducting oxides.

Education

• MS, Physics — Utah State University
• BS, Physics — University of California, Santa Barbara

Patents and technical contributions

Andy holds 19 U.S. patents, including 11 developed during his tenure at Raytheon, along with more than 30 trade secrets and over a dozen published papers and technology awards.