Patrick Morse: Plasma Physics and Vacuum Coating Expert & Educator

Patrick Morse is a seasoned expert with 20 years of experience in plasma physics and thin film deposition. With a strong track record of solving complex sputtering challenges and optimizing vacuum-based processes, Patrick specializes in creating Digital Twin simulations that bridge the gap between experimental results and theoretical predictions. He also shares his extensive knowledge as an Adjunct Instructor at the University of Arizona, teaching thin film deposition.

His career began at Advanced Process Technologies (later General Plasma Inc.), where he gained foundational knowledge in plasma-material interactions and magnetic confinement. At Sputtering Components Inc., he expanded his expertise to include molecular gas flow and electrical simulations, leading to the development of patented magnet bar designs used in numerous rotary cathode applications today.

Patrick’s problem-solving acumen is evident in his successful resolution of challenging production issues, including a notable case where he drastically improved reactive sputtering uniformity by optimizing a gas manifold design through COMSOL Multiphysics simulations. His ability to diagnose and address undocumented phenomena, such as plasma spokes and interactions between plasma development and process zone geometry, further underscores his expertise.

Patrick’s areas of expertise include large-area sputtering, PECVD sources, ion-beam etching, and Digital Twin simulations. He finds particular satisfaction in utilizing COMSOL Multiphysics to replicate and optimize real-world vacuum processes.

As a consultant with Arizona Thin Film Research LLC, Patrick leverages his extensive experience to help clients improve process efficiency and adapt to evolving industry challenges. He is passionate about sharing his knowledge and mentoring newcomers in vacuum coating technology, actively participating in events like TechCon and contributing to the Society of Vacuum Coaters (SVC).

Driven by a lifelong curiosity and a commitment to innovation, Patrick Morse continues to advance the field of vacuum coating through his analytical skills, practical experience, and dedication to continuous learning, now also through educating the next generation of thin film deposition experts at the University of Arizona.