Casey D. Foley, PhD

Casey D. Foley, PhD

Sensor Integration | Machine Vision & Imaging Systems | Advanced Laser Technologies | Mass Spectrometry Expert

Bridging Production Excellence with Advanced R&D Innovation

Technology integration specialist with 10+ years developing cutting-edge solutions across production, research, and scaling environments. Expert in translating advanced R&D concepts into production-ready systems, with extensive experience in high vacuum systems, laser technologies, and data science, achieving breakthrough results through cross-functional collaboration.

Key Achievements

99%
Process Yield Achievement

Achieved breakthrough 99% production yield through advanced metrology system design including confocal sensors, laser displacement sensors, and camera-based inspection systems with statistical process control.

3x
Manufacturing Efficiency

Reduced manufacturing takt time by 3x through strategic system upgrades and parameter optimization, and 50% reduction in another process through precision laser parameter tuning.

Advanced
ML Quality Control

Developed machine learning models for predictive glass surface topology control using advanced imaging metrology systems, currently optimizing accuracy through ongoing testing and validation.

$750K+
Instrument Recovery

Successfully restored complex triple quadrupole cryogenic ion trap mass spectrometer to full operation including high vacuum system rebuild, laser integration, and comprehensive method development.

Multiple
MS Platform Expertise

Expert proficiency across Waters, Thermo, and Bruker mass spectrometry platforms with ion mobility, ESI, MALDI, and nanoESI sources for diverse analytical applications.

22+
High-Impact Publications

Author of 22+ peer-reviewed publications including breakthrough papers in Science and JACS, demonstrating world-class analytical chemistry research capabilities.

Professional Experience

August 2024 - Present
Laser Systems Engineer
LuxWall

Designed and implemented advanced metrology systems achieving 99% process yield. Developed machine learning models for predictive quality control with ongoing optimization. Reduced manufacturing takt time by 3x through system optimization and automation. Subject matter expert for all laser and high vacuum processes.

2022 - July 2024
Research Excellence Postdoctoral Fellow
University of Missouri

Designed custom high vacuum imaging instrument to study hypersonic collisions. Implemented laser-based spectroscopic detection methods. Performed MeV-UED experiments at SLAC National Laboratory using advanced instrumentation systems and custom Python data analysis scripts.

2021 - 2022
Postdoctoral Associate
Sandia National Laboratories

Restored $750K+ triple quadrupole cryogenic ion trap mass spectrometer to full operation. Developed comprehensive method validation protocols for MS/MS and photofragmentation analysis. Built automated LabVIEW/MATLAB control systems for multi-instrument coordination.

2014 - 2016
Graduate Research Assistant
Wayne State University

Developed matrix-based ionization methods for mass spectrometry with mechanistic elucidation. Utilized multiple MS platforms including Waters, Thermo, and Bruker instruments with ion mobility for biological and polymer analysis. Taught analytical chemistry laboratory courses including chromatography and separation science.

2018
Summer Journeyman Fellow
Army Research Laboratory

Developed comprehensive silicon characterization workflow from wafer processing to particle fractionation. Implemented multi-modal analytical suite including FTIR spectroscopy, calorimetry, dynamic pressure measurements, and porosimetry analysis for silicon materials characterization.

Analytical Expertise

Mass Spectrometry & Separation Science

  • Waters Systems: QDa, q-IMS-TOF (Synapt G2/G2S) with ESI, nanoESI, and intermediate pressure MALDI sources
  • Thermo Systems: LTQ Velos, Orbitrap Fusion for high-resolution accurate mass analysis
  • Bruker Systems: ultrafleXtreme MALDI-TOF for proteomics and polymer analysis
  • Custom Instrumentation: Homebuilt triple quadrupole systems for cryogenic ion spectroscopy
  • Ion Mobility Expertise: Waters traveling wave IMS, collaborations with Prof. David E. Clemmer (Indiana University) and Dr. Richard D. Smith (Pacific Northwest National Laboratory)
  • Separation Science Background: PhD-level coursework, Waters UPLC system operation and method development, and extensive teaching of chromatographic principles and applications
  • Method Development: Comprehensive analytical protocol development for complex molecular systems
  • Interpretation of Complex Spectra: Expert analysis of MS/MS and photofragmentation spectra for structural elucidation

Advanced Spectroscopy

  • REMPI and Photoluminescence: Expert in laser-based spectroscopy.
  • FTIR Spectroscopy: ATR-FTIR, transmission, and photoacoustic methods for silicon and molecular analysis
  • UV/Vis/IR Spectroscopy: Methods for structure elucidation, including double resonance

Metrology & Quality Systems

  • Advanced Metrology Design: Confocal sensors, laser displacement measurement, camera-based inspection systems
  • Machine Vision Systems: Implemented sensors and cameras for precision process control
  • Statistical Process Control: Cp/Cpk analysis, process capability studies, and yield optimization
  • Method Validation: Comprehensive protocols for analytical method development and validation

Technical Skills

Analytical Chemistry & Mass Spectrometry

Waters (QDa, Synapt G2/G2S) Thermo (LTQ Velos, Orbitrap) Bruker (ultrafleXtreme) Ion Mobility (IMS-MS) ESI/MALDI/nanoESI MS/MS Method Development Peptide Fragmentation Custom MS Design

Advanced Spectroscopy

Photoluminescence Laser-Induced Fluorescence FTIR (ATR-FTIR) UV/Vis/IR Spectroscopy Photoacoustic Spectroscopy Silicon Characterization Electronic Spectroscopy Vibrational Analysis REMPI Double Resonance

Metrology & Sensor Integration

Confocal Sensors Laser Displacement Camera-Based Inspection Machine Vision Statistical Process Control Cpk/Ppk Analysis Process Capability Quality System Design

Programming & Machine Learning

Python MATLAB LabVIEW Machine Learning Data Analytics Statistical Analysis Automation Scripting Predictive Modeling

Advanced Instrumentation

Ultra-High Vacuum Systems Laser Systems Integration High Voltage Systems Thermal Analysis Ion Trajectory Simulation Particle Imaging

Manufacturing & Process Optimization

Root Cause Analysis (8D) PFMEA PDCA Cycle DOE KPI Development Yield Optimization Process Validation Contamination Control

Publications & Research Impact

22+
Peer-Reviewed Publications
Science
& JACS
Top-Tier Journals
350+
Citations
15+
Conference Presentations

Selected High-Impact Publications

Site-specific Photochemistry along a Protonated Peptide Scaffold
JACS, 146: 13282-13295, 2024
Advanced mass spectrometry and spectroscopic methods for understanding peptide photochemistry mechanisms.
Orbiting Resonances in Formaldehyde Reveal Coupling of Roaming, Radical, and Molecular Channels
Science, 374: 1122–1127, 2021
Breakthrough discovery using advanced imaging mass spectrometry and velocity map imaging technologies.
The Use of Ion Mobility Spectrometry-Mass Spectrometry (IMS-MS) to Elucidate Arm-Dispersity within Star Polymers
ACS MacroLetters, 4: 778–782, 2015
Innovative analytical method for characterizing complex polymer architectures using advanced separation science.
Molecular Cage Reports on Its Contents: Spectroscopic Signatures of Cryo-Cooled Complexes
J. Phys. Chem. A, 127: 6227–6240, 2023
Advanced spectroscopic analysis of host-guest molecular interactions using cryogenic methods.

Research Impact & Recognition

  • Cross-disciplinary Expertise: Published research spanning analytical chemistry, physical chemistry, materials science, and engineering
  • Method Development Leadership: Pioneered novel analytical approaches with successful technology transfer to production environments
  • International Recognition: Presentations at major scientific conferences and invited collaborations at national laboratories

Education

December 2020
PhD, Physical Chemistry
University of Missouri

Dissertation: Quantum Aspects of Roaming Dynamics
Advisor: Professor Arthur G. Suits
Focus on advanced particle imaging, spectroscopy, and method development. Extensive experience with instrumentation and laser system design.

May 2013
BS, Biochemistry
Saginaw Valley State University

Strong foundation in analytical chemistry and laboratory techniques. President's Scholarship recipient. Gained industrial experience working at Dow Chemical during undergraduate studies.

Get In Touch

Professional Contact

🌐
Website cdfoley.com

Professional Profiles

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Google Scholar View Publications

Current Availability

Open to discussing senior scientist and engineering opportunities in:

  • Machine Vision & Imaging Systems
  • Development of Laser Systems
  • Analytical Chemistry & Mass Spectrometry
  • High Vacuum Systems
  • R&D Technology Development
  • Cross-functional Technical Leadership
  • Advanced Metrology & Process Analytics
  • Quality Systems & Statistical Process Control