Patrick Lavery Email and Phone Number
Materials scientist with the ability to develop processes and materials that enhance many different technologies from commercial to government/military to space. Present work supports packaged/molded electronic power supplies used to power AI chips, servers, and a variety of other applications including specialty military devices in both terrestrial and space applications. Specialist in adhesion promotion, RF and MW plasma process applications, silicon MEMs, photo methods and techniques, electrolytic and electroless plating (Pt, Pd, Cu, Ni, NiP, Au), wet etch and cleaning processes, thin film materials and PVD methods, solders and SMT methods, fabrication of ferrite composites, filled polymers, refractories, high temperature metallurgy, coatings, and heat treat, inspection systems, and failure analysis using analytical equipment. Recent development leading to commercialized products include Vicor's SM-ChiP Family of power supples. Outlined and demonstrated the methods to externally metallize epoxy molded power supplies that allowed elimination of external leads thus making chips surface mountable. Make materials play nicely with each other and if needed invent them. Find every challenge interesting.
Vicor Corporation
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Senior Principal EngineerVicor Corporation May 2014 - PresentAndover, Ma, UsDeveloped materials and procedures utilizing new chemistries to advance 2D and 3D electronic packaging technologies. Latest development involved materials and methods to enhance adhesion of epoxy molding compounds to system in package (SIP) electronic assemblies used in lead-free solder assemblies. Improved MSL rating from MSL6 to MSL3. These packaged devices, SIP in type, contain not only both organic and inorganic materials but also solder which complicated the adhesion solution. Other activities, to name just a few, involved epoxy system integration, electroplating on epoxy molding compounds, PVD materials and methods, wet and dry etching, lithography, flip chips, and solder alloy development and processing. As a Senior Principal Engineer I support Design Engineering through the NPI process and I am always available for consultation with senior management and customers for product related issues. Co-author of several new product and process patents associated with the Vicor SM-ChiP, surface mount, and radiation tolerant systems. -
Principal Mems Process Design And Development EngineerLilliputian Systems Nov 2006 - May 2014MEMS Development. Solid Oxide Fuel Cell (SOFC) built on silicon MEMS structure. Developed platinum electroplating processes for silicon blind via fill, developed 3D, 40 micron thick polyimide /PBO structures with HDMS and Asahi Glass PBO, developed and released 800C operational thin film platinum electrodes and resistive heater networks, developed spray photolithography methods and spray resist with UV and Deep UV chemistries, and produced thin film Pt-YSZ structures with high temperature stability. Skilled in MEMs process equipment such at resist coaters, aligners, developer tools, wet sinks, plasma etchers (RIE and DRIE), EB-EVAP, Ion Beam Etcher, heat treat furnaces, and metrology equipment. Specialized ability in MEMS process integration as applied in Intel FAB17. -
Principal EngineerVicor Corporation Oct 2001 - Nov 2006Andover, Ma, UsWas company specialist in materials science technologies. Was Vicor lead in the qualification of ROHS compliant materials and MSL Testing in a lead-free solder environment. Was Vicor company expert in acoustic microscopy with over 2000 hour logged hours in the evaluation of MLPs. -
Thin Film Manufacturing Engineering ManagerFilm Microelectronics Inc/Satcon Technologies May 1998 - Sep 2001Thin film substrates and electronic networks built using thin film and plating techniques. Specialist in AlN substrate processing, hermetic filled Au vias, positive and negative resist processing, and high temperature stable films such as Ti/Pt/Au for 500C processing window that is wire bondable and adherent.
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Plant Metallurgist, Senior Development Engineer - Technical SupervisorUnited Technologies (Formerly Bf Goodrich Turbines/Walbar Metals Division) Nov 1991 - Jun 1998Developed high temperature coatings, including a co-deposition aluminum/chromium ATP coating for low Cr content Ni superalloys and pack and ATP platinum group metal enhanced aluminides. Patented new superalloy coatings. Supported multitple General Electric, Pratt and Whitney, Siemens, Westinghouse, and Solar Turbines programs. Represented Walbar when interfacing with customers such a GE and PWC on coating qualifications and new coating production methods.
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Program ManagerThermo Electron 1987 - 1991Waltham, Ma, UsThermolectric materials, SP-100 Space Power System, responsible for solid state and braze alloy bonding with graphite, CVD-W, Nb-1Zr, Ti, V, PdSi, and others. Worked on SiGe thermoelectric and TAGS (TeAgGeSe). Obtained FOM >2.0 with GSAT alloy material. Worked with GE-Astro Space Division, JPL (Jet Propopulsion Lab), and KAPL (Knowles Atomic Power Lab). Evaluated lifetime models for bonds of thermoelectric system used in Galileo probe that was sent to Jupiter. Held DOD Secret Clearance.
Patrick Lavery Education Details
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Thayer School Of Engineering At Dartmouth CollegeMaterials Sciences -
Thayer School Of Engineering At Dartmouth CollegeMetallurgical Engineering -
Dartmouth CollegeEngineering Sciences -
Phillips Exeter
Frequently Asked Questions about Patrick Lavery
What company does Patrick Lavery work for?
Patrick Lavery works for Vicor Corporation
What is Patrick Lavery's role at the current company?
Patrick Lavery's current role is Senior Principal Engineer: MEMS, Materials Scientist and Metallurgist, Electronics Packaging, Thin Film and Etch Processing.
What schools did Patrick Lavery attend?
Patrick Lavery attended Thayer School Of Engineering At Dartmouth College, Thayer School Of Engineering At Dartmouth College, Dartmouth College, Phillips Exeter.
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