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Senior R&D Engineer · Chemical Engineer

I develop materials and processes that move from lab to production.

I'm Sergio Fernandez, an MIT-trained engineer with 12+ years of experience developing and scaling advanced materials, electrochemical systems, and coating processes.

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Electrolysis✦Membranes✦Coatings✦Catalysis✦Scale-up✦Commercialization
01 / Career path

A career built across research, process development, and manufacturing.

My work has moved from catalyst and reactor research to protective coatings, electrolyzer materials, and membrane manufacturing.

2016 — 2020 · 7 publications

2019 — 2024 · 6 patents & applications

2023 · 3 granted patents

Aramco Americas2014 — 2020
GVD Corporation2020 — 2023
EH22023 — 2024
Ionomr Innovations2024 — Present
Aramco AmericasGVD CorporationElectric HydrogenIonomr InnovationsPublication periodPatent activity
02 / Approach

From laboratory research to reliable production.

I work across materials development, process design, equipment, quality, and manufacturing to turn laboratory results into repeatable production methods.

Scale-up pathway from laboratory formulation and screening, through pilot process and equipment development, to manufacturing transfer and qualification.
Illustrative scale-up pathway. The 750,000 m²/year figure refers to the publicly reported annual membrane-production capacity of Ionomr's Boston facility.
03 / Selected projects

Technical problems, methods, and results.

Two examples showing the problem, my contribution, and the result.

Non-confidential summaries.
01

GVD Corporation · Electronics protection coatings

Improving coating conformality by 2×

2×increase in coating conformality
Problem
Existing deposition processes did not provide enough conformal coverage for complex semiconductor assemblies that required reliable polymer protection.
Approach
Developed and evaluated PECVD and iCVD equipment and process changes, using substrate inspections and quality checks to compare results.
Result
Achieved a 2× increase in coating conformality and helped qualify PECVD production chambers for external customers.
Illustrative coating comparison: uneven coverage leaves a gap in a recessed feature; conformal coating follows the full surface.
Illustrative schematic of the process concept.
  1. 01Identify coverage gaps
  2. 02Develop and test changes
  3. 03Qualify production chambers
02

Electric Hydrogen · PEM electrolysis

Scaling catalyst production to kilogram capacity

kginternal catalyst production capacity
Problem
A new OER catalyst process needed to meet the consistency, quality, and supply requirements of large-scale PEM electrolyzer manufacturing.
Approach
Advanced the catalyst process, established incoming-powder metrology, and worked with manufacturing to transfer inks, coatings, and CCMs from R&D.
Result
Scaled internal catalyst production to kilogram capacity and supported the transition of materials and processes into full-scale production.
Illustrative PEM electrolyzer cross-section showing the membrane and catalyst layers, water input, separate hydrogen and oxygen outputs, and catalyst production progressing from bench to kilogram scale.
Illustrative schematic of the process concept.
  1. 01Develop the catalyst process
  2. 02Establish quality controls
  3. 03Transfer to manufacturing
Aramco R&D

Two moments from my work with the Advanced Materials team at Aramco Americas.

Sergio Fernandez showcasing Aramco materials research and innovation at a Materials Research Society meeting in Boston
Research showcase Showcasing Aramco materials research and innovation at the Materials Research Society meeting in Boston, MA.
Sergio Fernandez operating an X-ray diffractometer in an Aramco Americas laboratory
Characterization Operating an X-ray diffractometer to characterize advanced materials developed by Aramco's Advanced Materials team.
04 / Experience

Materials development and process scale-up.

Experience across electrolysis, coatings, catalysis, and advanced manufacturing.

01
2024 — Present

Ionomr Innovations Inc. · Boston, MA

Senior R&D Engineer

Lead polymer formulation and membrane development, translating laboratory results into a pilot coating process designed for 750,000 m² of annual production.

  • Developing and testing Aemion® ionomer formulations, additives, and inorganic components to improve performance and mechanical durability.
  • Advancing cross-linking chemistry for alkaline-stable membranes with improved conductivity and solvent resistance.
  • Evaluating functional layers and material combinations to support membrane performance and durability.
  • Identifying solvent systems and polymer blends that improve hydrophilicity and mechanical reinforcement.
02
2023 — 2024

Electric Hydrogen Co. · Natick, MA

Senior Chemical Engineer

Led catalyst development, protective coating work, and process scale-up for PEM electrolyzer manufacturing.

  • Designed and advanced next-generation iridium-based oxygen-evolution electrocatalysts using novel processing methods to improve performance and reduce degradation.
  • Scaled internal catalyst production to kilogram capacity.
  • Transitioned ink formulations, coatings, and CCMs from R&D into full-scale production.
  • Established catalyst recovery and recycling programs and mentored engineers and co-ops.
03
2020 — 2023

GVD Corporation · Cambridge, MA

R&D Engineer · Process Engineer

Developed PECVD and iCVD equipment and processes for applying conformal polymer coatings to electronics and energy materials.

  • Developed a coating process that doubled conformality.
  • Qualified PECVD production chambers for external customers, supporting commercialization.
  • Supported DOE-funded work on perovskite barriers and ion-exchange membranes.
  • Served as Chemical Hygiene Officer, coordinating quarterly safety meetings and inspections and promoting safe laboratory practices.
04
2014 — 2020

Aramco Americas · Cambridge, MA

Lab Scientist II & III

Designed catalytic materials, reactor systems, and scale-up routes for converting hydrocarbon feedstocks into higher-value chemicals.

  • Scaled novel catalyst synthesis for pilot-plant testing.
  • Developed a hydrocracking process using a four-channel reactor system for catalyst testing at elevated temperatures and pressures.
  • Developed spray-drying, aerosol synthesis, forming, and pelletizing processes.

Early experience

2013

The Dow Chemical Company

Manufacturing & Engineering Intern

Manufacturing engineering within the Rohm and Haas Chemicals engineering division.

2012 — 2013

MIT Institute for Soldier Nanotechnologies

Undergraduate Researcher

Undergraduate research within MIT's interdisciplinary soldier nanotechnology institute.

2012

Corning Incorporated

R&D Intern

Materials Science Technology research and development internship.

2011 — 2012

MIT · Myerson Research Group

Undergraduate Researcher

Undergraduate chemical engineering research in the Myerson Research Group.

05 / Expertise

Technical expertise across materials and process scale-up.

Methods and tools I use to develop, characterize, scale, and transfer new materials and processes.

Scale-up & manufacturing

Pilot systems · Process development · Facility commissioning · Powder, ink & coating processes

Materials & electrochemistry

PEM / AEM membranes · OER catalysts · CCMs · PECVD / iCVD · Zeolites · Surface modification

Characterization

BET / DFT / BJH · XRD · SEM / TEM / EDS · TGA / DSC · GC · ICP-OES · Mechanical testing

Modeling & tools

Python · MATLAB · COMSOL · LabVIEW · Aspen Plus · OpenFOAM · 3D printing & prototyping

06 / Research & patents

Publications, patents, and recognition.

Research and inventions in catalysis, zeolites, coating processes, and reactor systems.

7Selected publications
6Patents & applications
3Career awards
Featured patent

Multi-functional composite catalyst materials and methods of synthesizing the catalyst materials

US Patent 11,369,950 · Granted June 2022

Recognition

2018Best Presentation · ACS National Meeting, CATL Session
2017Delivered Technology Award
2017Best Presentation Award · AIChE National Meeting
07 / Education

Massachusetts Institute of Technology

B.S. Chemical Engineering

Cambridge, MA · 2014

Chemical engineering training in kinetics, reactor design, thermodynamics, transport, separations, and energy.

Contact

Let's connect.

I welcome conversations about materials research, process development, and the challenges of bringing new technologies into production.

sfernand2408@gmail.com LinkedIn Google Scholar