Battery Cell Process Engineer (Pilot Line / Prototyping)

Position Overview

We are seeking a detail-oriented Battery Cell Process Engineer to support the fabrication, assembly, and prototyping of next-generation high-energy battery technologies. In this role, you will work closely with senior process and cell design engineers to operate and maintain lab-scale pilot line equipment, fabricate pouch cells, optimize assembly parameters, and ensure high manufacturing yield, quality, and repeatability across experimental builds.

Key Responsibilities & Deliverables

• End-to-End Pouch Cell Fabrication: Support complete pilot-line cell assembly, including slurry mixing, electrode coating (slot-die/doctor-blade), calendering, slitting/die-cutting, precision stacking, tab welding, pouch sealing, electrolyte filling, and formation.

• Equipment Operation & Maintenance: Operate, calibrate, and maintain dry room systems, glove boxes, pilot-line tooling, and assembly equipment to preserve baseline process capabilities.

• Process Optimization & DOEs: Execute Design of Experiments (DOEs) to identify Critical Process Parameters (CPPs) and optimize cell yield, thickness uniformity, loading density, and energy density.

• Quality Assurance & Defect Analysis: Perform in-line quality inspections (e.g., seal integrity, alignment checks), log build metrics into tracking databases, and troubleshoot fabrication defects (e.g., coating pinholes, delamination, stacking misalignment, poor wetting).

• Documentation & Safety Standards: Author and update Standard Operating Procedures (SOPs), assembly traveler logs, and safety protocols for new battery chemistries and form factors, ensuring strict adherence to hazardous materials handling.

Minimum Qualifications

• Education: Bachelor’s degree in Materials Science, Chemical Engineering, Mechanical Engineering, Electrical Engineering, or equivalent practical experience.

• Pilot Line Experience: 1+ years of practical, hands-on experience operating lab-scale pilot line equipment for pouch cell fabrication.

• Cleanroom / Dry Room Skills: Direct laboratory experience handling battery active materials, chemical reagents, and precision mechanical assembly tools.

• Process Knowledge: Practical understanding or coursework in lithium-ion manufacturing workflows (slurry preparation, coating, calendering, stacking, electrolyte filling).

• Operational Discipline: Strong documentation habits, acute attention to detail with delicate components, and compliance with lab safety protocols.

Preferred Qualifications

• Specialized experience operating automated tab welding (ultrasonic/laser) and vacuum electrolyte filling/sealing machinery.

• Familiarity with Statistical Process Control (SPC), yield analysis, and data analysis tools (Python, MATLAB, JMP, or advanced Excel).

• Functional understanding of how upstream slurry and coating variations impact downstream electrochemical performance and cell degradation.