A division of Applied Materials Inc. in Gloucester, MA, had a severe problem with their plasma flood gun, which is an electron source used to charge-neutralize the silicon wafer during high energy ion implantation. The existing technology involved a heated tungsten element used in generating electrons, with severe contamination limitations, in which high amounts of tungsten was invariably observed on the wafer. The situation was grim as the company’s customers were moving toward more sophisticated processes that demanded much lower metal contamination limits. Emphysys, a technology development company, was engaged to invent and bring to fruition a much cleaner (contamination-free) xenon plasma solution used to source the electrons. Emphysys developed a new and novel high-density clean plasma source which eventually replaced the customer’s tungsten technology. Along with the plasma technology, Emphysys also developed the required power delivery system.
Being at the intersection of mechanical, electrical, software, and science domains, Emphysys has an envious position in the market. Companies from the medical device, life sciences, and industrial equipment industries often find Emphysys as the missing piece of their new product development puzzle. Led by a talented team of seasoned scientists and engineers, the company has extensive experience in the areas of technical consulting and product development. It has a proven history of developing state-of-the-art solutions in relation to RF, microwave, plasma systems and processing that solve some of the most serious technical challenges for their customers.
“With the kind of expertise and experience we have, Emphysys has turned into a well-oiled machine that delivers high-value technology and products rapidly,” says Ali Shajii, founder and CEO of the company.
When Emphysys entered the business, most of the capital equipment companies were entrenched with making profit. This focus on profit deprived R&D groups of the talent required to drive revolutionary ideas and innovation. “It is extremely difficult to build a team like ours,” says Shajii. Customers have grown accustomed to using Emphysys as a partner for innovation.
“Other engineering services companies in the industry are ‘meat and potatoes’ development companies who develop products based on pre-defined specifications,” says Shajii. “We are different. Companies approach us when they have a problem and are looking for a solution through new technologies and resulting IP generation.”
When it comes to customer engagement, Emphysys follows a fixed bid contract model where payments are tied to deliverables so both the customer and Emphysys have a critical stake in the success of the project. During customer interactions, Emphysys engages with senior executives and clearly communicates the technological or project uncertainties that may crop up during the execution. This gives customers the confidence to calculate the tangible ROI and reach their goals in budget and in time.
Started in 2009 with five people, Emphysys has been growing steadily at an average of 25 percent annual growth over the last four years. Moving ahead, it aims to grow in the medical devices and life sciences industries and maintain its position in industrial equipment. The firm follows unique hiring strategies that are aligned with its values and technical outlook. “We see the semiconductor industry contributing to 20-30 percent of our business, but we also strive to make our impact in other industries to balance our customer mix,” ends Shajii.