• Consulting on problems of reproducibility in manufacturing
  • Problems with long-term stability of functional properties of coated products
  • Best practices for handling and cleaning of materials and equipment
  • Preparation of documentation, process monitoring and control
  • Adhesion testing and accelerated aging studies
  • Development of “robust” processes
  • Assistance in the Discovery Process for patent litigation

Donald M. Mattox

Donald M. Mattox is the MPI principal responsible for providing consulting services.



B.S. Physics. Eastern Kentucky State University, Richmond, KY

Meteorology (USAF). Massachusetts Institute of Technology (MIT), Cambridge, MA

Served as Meteorologist and Air Weather Officer in US Air Force

M.S. Solid State Physics. University of Kentucky, Lexington, KY

Experience in Vacuum Technology and Vacuum Coating Industries

Technical staff and supervisor – Sandia National Laboratories, Albuquerque, NM.  Retired as supervisor of Surface and Interface Technology Division (responsible for: vacuum coating, vacuum plasma spraying, electrodeposition, chemical vapor deposition, surface cleaning and contamination control, technology transfer from laboratory to production, production troubleshooting)

1985- present
Co-founder, Management Plus, Inc.

Consultant, Vacuum coating industry

Instructor, vacuum technology and vacuum coating technology – industry & technical societies

Author, vacuum coating technology, history of vacuum coating technology and enabling technologies

Instructor, American Vacuum Society  (AVS)

Instructor, Materials Research Society (MRS)

Instructor, Society of Vacuum Coaters (SVC)

Technical Director, Society of Vacuum Coaters

Technical Editor, Society of Vacuum Coaters

Technical Director, Association of Vacuum Equipment Manufacturers

Technical Editor, Vacuum Technology & Coating magazine

Honors and Awards

President – American Vacuum Society

Award Plaque – The 9th International Congress on Vacuum Metallurgy, commendation for “outstanding contributions to metallurgical coating technology for the period 1961-1988”

AVS Emeritus Member

Award – American Vacuum Society (AVS) Albert Nerken Award: “For his invention of the ion-plating process and its continued development”

Fellow – American Vacuum Society

Award – Society of Vacuum Coaters (SVC) Inaugural Mentor Award

Award Plaque – SVC Board named the noon hour Technical Conference Tutorial as the Donald M. Mattox Tutorial Program. Awarded a Life time membership in SVC.

Award Plaque –  “Life for Thin Films” – Conference of European Vacuum Coaters, Anzio, Italy

Award – Society of Vacuum Coaters (SVC), Nathaniel H. Sugerman Memorial Award: “For his development of the ion plating process, long-term commitment to education in the vacuum coating community, and outstanding service to the SVC”

Some Recent and Significant Publications and Patents

Books Authored

Foundations of Vacuum Coating Technology, 2nd edition, Elsevier – in press (2018)

Handbook of Physical Vapor Deposition (PVD) Processing, 2nd edition, Elsevier (2010)

Education Guides to Vacuum Coating Processing, Society of Vacuum Coaters (2009)

Foundations of Vacuum Coating Technology, 1st edition, Noyes publication (2003)

Handbook of Physical Vapor Deposition (PVD) Processing, 1st edition, Noyes/Elsevier (1998)

Books Co-edited

50 Years of Vacuum Coating Technology and the growth of the Society of Vacuum Coaters, edited by Donald M. Mattox and Vivienne Harwood Mattox, Society of Vacuum Coaters (2007)

Adhesion in Solids, MRS Proceedings vol. 119 edited by D.M. Mattox, J.E.E. Baglin, R.J. Gottschall, and C.D. Batich, Material Research Society (1988)

Deposition Technologies for Films and Coatings, edited by R.F. Bunshah et al, Noyes Publications (1982)

Book Chapters/Articles

“Non-elemental Characterization of Films and Coatings,” D.M. Mattox, Ch. 15 in Handbook of Deposition Technologies for Films and Coatings, 3rd edition, edited by Peter M. Martin, Elsevier (2010)

“Surface Preparation for Film and Coating Deposition Processes,” D.M. Mattox, Ch. 3 in Handbook of Deposition Technologies for Films and Coatings, 3rd edition, edited by Peter M. Martin, Elsevier (2010)

“Ion plating,” D.M. Mattox, Ch. 6 in Handbook of Deposition Technologies for Films and Coatings, 3rd edition, edited by Peter M. Martin, Elsevier (2010)

“The Transfer of Technology from Research and Development to Manufacturing,” D.M. Mattox, Appendix 1, p. 545-552 in Handbook of Physical Vapor Deposition (PVD) Processing, 2nd edition, Elsevier (2010)

“Substrate Cleaning,” Section E1, Donald M. Mattox, in Thin Film Process Technology, edited by David A. Glocker and S. Ismat Shah, Institute of Physics (IoP) Publishing (2002)

“Preparation and Cleaning of Vacuum Surfaces,” D.M. Mattox, Ch. 4.9 in Handbook of Vacuum Science and Technology, edited by Dorothy M. Hoffman, Bawa Singh, and John H. Thomas III, Academic Press (1998)

“Ion Plating,” D.M. Mattox, Ch. 13, p. 338 Handbook of Plasma Processing Technology, edited by S. M. Rossnagel, J.J. Cuomo, and W.D. Westwood, Noyes Publications (1989)

“Residual Stress, Fracture and Adhesion in Sputter-Deposited Molybdenum Films,” D.M. Mattox and R.E. Cuthrell, MRS Proceedings Volume 119, p. 141, Adhesion in Solids, edited by D.M. Mattox, J.E.E. Baglin, R.J. Gottschall and C.D. Batich (1988)

“Thin Film Adhesion and Adhesive Failure – A Perspective,” D.M. Mattox, pp. 54-62 in Adhesion Measurement of Thin films, Thick films and Bulk Coatings, edited by K. Mittal, ASTM STP 640, American Society for Testing and Materials (1978)

Technical Articles

“Ion Plating – Past, Present and Future,” D.M. Mattox, Surf. Coat. Technol. 133/134, 517 (2000)

“Preparation of Thick Stress-free Mo Films for a Resistively Heated Ion Source,” D.M. Mattox, R.E. Cuthrell, C.R. Peeples and P.L. Dreike, Surf. Coat. Technol. 36, 117-124 (1988)

“Properties of Coated and Modified Surfaces,” D.M. Mattox, J.E. Greene, D.H. Buckley and G.A. Somorjai, Mater. Sci. Eng. 70, 1-89 (1985)

“Thermal Fatigue Properties of Coated Materials for Fusion Device Applications,” A.W. Mulendore, J.B. Whitley and D.M. Mattox, J. Nucl.Mat. 103-104, 181 (1981)

“Optical Properties and Composition of Electroplated Black Chrome,” R.R. Sowell and D.M. Mattox, Plat. Surf. Finish. 65, 50 (1978)

“Reactive Plasma Cleaning of Metals,” G.J. Kominiak and D.M. Mattox, Thin Solid Films 40, 141 (1977)

“Optical Materials for Solar Energy Applications,” D.M. Mattox, Optics News 2(3) 12 (1975)

“Solar-Energy Materials Preparation Techniques,” D.M. Mattox, J. Vac. Sci. Technol. 12(5) 1023 (1975)

“Surface Cleaning by Ultraviolet Radiation,” R.R. Sowell, R.E. Cuthrell, R.D. Bland and D.M. Mattox, J. Vac. Sci. Technol. 11, 474 (1974)

“Deposition of Metal Films by Laser-controlled CVD,” R.S. Berg and D.M. Mattox, Proc 144th American Electrochemical Society Meeting, 73-2, #212 (1974)

“Fundamentals of Ion Plating,” D.M. Mattox, J. Vac. Sci. Technol. 10, 47 (1973)

“Structure Modification by Ion Bombardment During Deposition,” D.M. Mattox and G.J. Kominiak, J. Vac. Sci. Technol. 9, 528 (1972)

“Aluminum Coating of Uranium Reactor Parts for Corrosion Protection,” D.M. Mattox and R.D. Bland, J. Nucl. Mater. 21, 349 (1967)

“Film Deposition Using Accelerated Ions,” D.M. Mattox, Electrochem. Technol. 2, 295 (1964)


“Apparatus for Coating a Cathodically Biased Substrate from Plasma of Ionized Coating Material,” D.M. Mattox, US Patent # 3,329,601 (July 4,1967)