Casey D. Foley, PhD

Casey D. Foley, PhD

Laser and Vacuum Systems | R&D | Production Optimization | Instrumentation | Machine Vision

Bridging Industrial Process Development with Advanced Scientific Instrumentation

PhD physical chemist and laser systems engineer with 10+ years of experience across production, national laboratory, and university research environments. Expert in laser process development, high vacuum systems, machine vision, and sensor integration — with a track record of achieving measurable production outcomes and a foundation in advanced spectroscopy, mass spectrometry, and imaging.

Key Achievements

99%
Laser Process Yield

Achieved 99% yield independently across two separate laser ablation processes through sensor integration, process design, and statistical process control.

Takt Time Reduction

Reduced manufacturing takt time 3× across multiple systems via strategic laser upgrades, parameter optimization, and Python-based automation.

VIG Throughput Increase

Led development of a proprietary vacuum insulated glass evacuation process achieving 2× throughput, 99% yield, and improved unit R-Value.

$1M+
Instrument Recovery

Fully restored a cryogenically-cooled ion trap mass spectrometer including UHV system rebuild, laser integration, and control software programming.

ML and Vision
Intelligent QC Systems

Applied machine learning and machine vision to glass surface inspection and quality control — including deployment of a single glass plane defect detection system.

20+
Peer-Reviewed Publications

Author of 20+ publications including papers in Science and JACS with 430+ citations, demonstrating deep scientific expertise across analytical and physical chemistry.

Professional Experience

August 2024 – Present
Laser Systems Engineer
LuxWall
  • Integrated fiber laser ablation system, achieving 99% yield and 3× takt time reduction; separately achieved 99% yield and 2× takt time reduction on a second ablation process through sensor integration and SPC
  • Led development of vacuum insulated glass (VIG) evacuation process in first factory, achieving 2× throughput increase, 99% yield, and improved unit R-Value
  • Led development of laser heating processes for vacuum insulated glass production
  • Served as cross-functional technical liaison between factory engineering, scaling, and R&D teams
  • Deployed single glass plane defect detection system in collaboration with vision system integrator; integrated material color measurement system; applied ML and machine vision for QC
  • Subject matter expert for all laser and high vacuum processes — authored SOPs, work instructions, control plans, and troubleshooting guides; overhauled preventative maintenance procedures
2022 – July 2024
Research Excellence Postdoctoral Fellow
University of Missouri
  • Designed and built custom ultra-high vacuum imaging instrument for hypersonic collision studies with electron-ion coincidence detection
  • Implemented laser system for novel VUV detection of atoms and molecules; performed MeV-UED experiments at SLAC National Laboratory using advanced instrumentation and custom Python analysis
  • Mentored research group members and led lab operations as senior postdoc
2021 – 2022
Postdoctoral Associate
Sandia National Laboratories
  • Restored $1M+ cryogenically-cooled ion trap mass spectrometer including UHV system rebuild, tunable IR OPO/OPA laser installation, and programming of LabVIEW control and data analysis software
  • Developed IR, UV, and double resonance spectroscopy methods for novel molecular detection and structural characterization of metal–molecule complexes
May 2016 – 2020
Graduate Research Assistant
University of Missouri
  • Published breakthrough research in Science on quantum resonances in molecular dynamics using velocity map imaging
  • Designed comprehensive laser automation systems and custom optical detection for UHV molecular beam experiments
2014 – April 2016
Graduate Research Assistant
Wayne State University
  • Developed mass spectrometry methods across Waters, Thermo, and Bruker platforms with ion mobility spectrometry for biological and polymer analysis
  • Taught analytical chemistry laboratory courses including chromatography and separation science
Summer 2018
Summer Journeyman Fellow
Army Research Laboratory
  • Developed porous silicon particle workflow from wafer to fractionated particle; characterized materials via FTIR, calorimetry, dynamic pressure measurements, and porosimetry for energetic materials applications

Technical Skills

Laser Systems

Fiber Laser Nd:YAG / DPSS CO₂ Excimer VUV / Ti:Sapphire IR OPO/OPA Laser Ablation Laser Scribe Laser Heating Optical Alignment Beam Diagnostics

Vacuum and Advanced Instrumentation

Ultra-High Vacuum Systems Ion Optics Cryogenic Systems Mass Spectrometry (Waters, Thermo, Bruker) Ion Mobility (IMS-MS) Particle Imaging Velocity Map Imaging High Voltage Systems

Sensor Integration and Machine Vision

Confocal Sensors Laser Displacement Camera-Based Inspection Defect Detection Systems Color Measurement Machine Vision Integration

Programming and Data Science

Python MATLAB LabVIEW Machine Learning Data Analytics Automation Scripting Data Acquisition

Spectroscopy and Analytical Chemistry

UV/Vis/IR Spectroscopy FTIR (ATR, Transmission) REMPI Double Resonance Laser-Induced Fluorescence Photofragmentation ESI / MALDI / nanoESI MS/MS

Process Engineering and Production Improvement

Process Development Yield Optimization Statistical Process Control Cpk/Ppk Analysis Root Cause Analysis (8D) PFMEA PDCA DOE SOP Authoring Control Plans Preventative Maintenance KPI Development CAD (SolidWorks, FreeCAD)

Publications and Research

20+
Peer-Reviewed Publications
430+
Citations
Science
& JACS
Top-Tier Journals
15+
Conference Presentations

Selected Publications

Site-specific Photochemistry along a Protonated Peptide Scaffold
Journal of the American Chemical Society, 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 velocity map imaging and advanced laser systems to observe quantum resonances in molecular unimolecular dissociation.
Molecular Cage Reports on Its Contents: Spectroscopic Signatures of Cryo-Cooled K⁺- and Ba²⁺-Benzocryptand Complexes
Journal of Physical Chemistry A, 127: 6227–6240, 2023
Advanced spectroscopic analysis of host-guest molecular interactions using cryogenic ion trap methods.
Ion Mobility Spectrometry-Mass Spectrometry to Elucidate Arm-Dispersity within Star Polymers
ACS MacroLetters, 4: 778–782, 2015
Innovative analytical method for characterizing complex polymer architectures using ion mobility separation.

Full publication list available on Google Scholar

Education

December 2020
PhD, Physical Chemistry
University of Missouri

Dissertation: Quantum Aspects of Roaming Dynamics
Advisor: Professor Arthur G. Suits
Advanced particle imaging, spectroscopy, laser system design, and UHV instrumentation. Research Excellence Fellowship recipient.

May 2013
BS, Biochemistry
Saginaw Valley State University

President's Scholarship recipient. Gained industrial laboratory experience at Dow Chemical during undergraduate study.

Get In Touch

Contact

💼
🎓
Google Scholar View Publications
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Website cdfoley.com

Open To

Senior scientist and engineering roles, and open to consultation, in:

  • Laser Systems
  • Vacuum Systems
  • Instrumentation
  • Novel Optical Detection Methods
  • Machine Vision and Imaging
  • Process Development and Scale-Up
  • R&D Technology Development
  • Analytical Chemistry
  • Cross-Functional Technical Leadership