DANE KELLEY
Indian Hills,CO
Summary
Process focused Metallurgical and Materials Engineer with 8 years of experience at CoorsTek, specializing in ceramic manufacturing, tapecasting, and rare earth recycling processes. Demonstrated ability to analyze data, identify root causes, and implement process improvements that enhance yield, efficiency, and product quality. Strong background in material characterization and failure analysis, with a collaborative approach to solving complex manufacturing challenges and supporting cross-functional teams in dynamic production environments.
Overview
8
8
years of professional experience
Work History
Research & Development Technical Specialist
CoorsTek
10.2024 - Current
- Scaled and operationalized a rare earth recycling process from external concept to internal pilot production, processing ~500 kg of material in controlled batch runs while achieving >90% recovery efficiency and low impurity levels, supporting strategic expansion into rare earth recycling capabilities for both internal operations and external customers
- Designed and executed experimental studies to optimize process parameters, reduce contamination, and improve overall yield using data driven analysis
- Owned end-to-end process execution, including material flow, equipment setup, and performance monitoring, enabling transition from R&D to production-ready capability
- Partnered with cross-functional teams (Advanced Materials Processing, Analytical Chemistry, and Manufacturing) to evaluate equipment, refine process flow, and support pilot line implementation
- Led data management and standardization efforts in collaboration with computational engineering to structure datasets for database integration and future machine learning applications
- Analyzed datasets to identify trends, improve process consistency, and support decision-making for process optimization and scale-up
- Delivered monthly technical reports and project updates to senior leadership, communicating key metrics, progress, risks, and strategic direction
- Developed and maintained detailed technical documentation, including process procedures, experimental protocols, and system functionality guidelines
- Coordinated evaluation of liquid and solid samples through analytical testing to support process validation and quality control
Research and Development Technician
CoorsTek
06.2018 - 10.2024
- Served as process owner and technical lead for ceramic tape casting operations supporting aerospace and semiconductor applications, driving process stability, material performance, and production readiness
- Optimized tape casting formulations through detailed analysis of organic constituents, improving lamination quality, reducing defects, and enhancing final material performance
- Led cross-functional efforts to transition a semiconductor tape casting process from R&D to full production, collaborating with engineering, manufacturing, and facilities teams to integrate new equipment and establish robust process flow
- Owned process area equipment and performance, maintaining operational efficiency, troubleshooting issues, and ensuring compliance with safety and quality standards
- Designed and executed structured experimental plans, leveraging data analysis to refine process parameters and guide continuous improvement initiatives
- Managed and analyzed experimental datasets, partnering with computational engineering to implement sequential learning techniques that improved experimental efficiency and accelerated development cycles
- Provided regular technical updates to stakeholders, including process performance metrics, improvement initiatives, and equipment status
Education
Bachelor of Science - Metals and Materials Engineering
Colorado School of Mines
Golden, CO05-2026
Associates of Engineering Science -
Red Rocks Community College
01-2023
Skills
- Process Optimization
- Continuous Improvement (6S)
- DOE
- Data Analysis (JMP)
- Brazing
- Metallization
- Electrodepostion Plating
- Equipment Ownership and Commissioning
- Process Scale-Up
- SOP Development
- Microsoft Office
- Safety & EHS (ERT, Hazardous Waste, CPR/First Aid)
Timeline
Research & Development Technical Specialist
CoorsTek
10.2024 - Current
Research and Development Technician
CoorsTek
06.2018 - 10.2024
Bachelor of Science - Metals and Materials Engineering
Colorado School of Mines
Associates of Engineering Science -
Red Rocks Community College