Andrew P. Clarke

Consultant overview

Andy Clarke has spent 35 years developing reliable products and processes. His work has resulted in 19 U.S. patents, produced more than 30 critical trade secret filings and over a dozen published papers and technology awards. His training and experience have shaped a broad, physics-informed expert skill set that spans plasma processing, product development, and lean manufacturing.

He has helped clients and past employers resolve costly product design and manufacturing problems, often by identifying and developing simple, low-cost solutions.

How Andy can help

Andy helps companies solve complex technical and manufacturing challenges involving vacuum technology, capital equipment, failure analysis, materials integration, process reliability, yield, and cycle time. They also provide experienced support for invention patentability analysis, including prior art research, comparative analysis, and patent specification writing. Expert witness service in trade secret disputes and preparation of expert declarations are also offered.

• 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

If a technical or manufacturing problem is costing your company money, but your team is too busy to give it the focused attention it requires, an outside perspective can help. Andy brings practical experience, technical depth, and a fresh point of view to help identify the root cause and develop an effective path forward.

Schedule a free 20-minute telephone consultation to discuss your situation. If the problem is a good fit for Andy’s expertise, he will provide his rates, terms, and availability.

Confidentiality: All communication is handled with absolute discretion.

Selected experience

PVD Technology Director, Plasma-Therm LLC (2023–2026) Managed product development for two PVD product lines.

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 manufacturing, process, materials and equipment solutions; served as expert witness in patent and trade secret litigation.

VP & General Manager, PVD Products Division, Tegal Corporation (2004–2006)

Founder & CEO, First Derivative Systems, Inc. (1999–2004)

Senior VP, Sputtered Films, Inc. (1989–1999)

US DOE Graduate Fellow, Los Alamos National Laboratory (1987–1989)

Education

• MS and BS Physics

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.