Andrew P. Clarke

Consultant overview

Andy Clarke has spent more than thirty years turning thin-film physics into manufacturable processes and profitable products. He has directed PVD technology strategy at Plasma-Therm, developed detector and IC integration processes at Raytheon, founded and sold a deposition equipment company, and scaled another from under $1M to more than $20M in revenue. Along the way he has earned 19 U.S. patents and served as an expert witness in patent and trade secret litigation.

How Andy can help

• PVD and thin-film process development — bringing new film stacks to spec, and finding root cause when a qualified process drifts
• Yield and manufacturability — failure analysis and process changes that survive contact with production
• Capital equipment strategy — tool selection and acceptance, technology roadmaps, budgets, and program timelines
• Expert witness engagements — testimony and technical analysis in patent and trade secret litigation

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 developed through cross-functional innovation efforts.

Engagement approach

Each engagement begins by defining the decision to be made, the evidence available, and the assumptions that require testing. The goal is a technically sound path forward that remains legible to the people responsible for carrying it into production.