Principal Process Engineer Battery Cell Assembly and Formation
Blue CurrentHayward, California
Full Time
Posted October 29, 2025
$175k - $230k
Apply Now
Application opens on company website
Job Description
A Principal Process Engineer responsible for leading the development and optimization of cell assembly manufacturing processes for solid-state batteries, ensuring quality, reliability, and scalability in a fast-paced, innovative environment.
Key Responsibilities
- Lead the design and development of battery cell assembly processes on the pilot line.
- Provide technical guidance, coaching, and leadership to engineering and technician teams.
- Optimize manufacturing parameters to improve performance, yield, and throughput.
- Develop and implement process control strategies and specifications for pilot manufacturing.
- Create training materials and train personnel in cell assembly processes.
- Design and implement statistical process control systems for critical parameters.
- Generate machine specifications and collaborate with suppliers to develop pilot equipment.
- Partner with R&D to transition laboratory processes to pilot manufacturing.
- Lead technology transfer activities to contract manufacturers or partners.
- Scale production processes to meet internal and customer volume requirements.
Requirements
- BS in Chemical Engineering, Materials Science, Mechanical Engineering, Industrial Engineering, or related fields.
- MS or PhD preferred.
- 8 years experience working with lithium-ion battery, fuel cell, capacitor or semiconductor manufacturing processes and production equipment.
- Proven ability to lead cross-functional teams and drive results.
- Experience working with lithium-ion battery manufacturing equipment such as Die and punch, electrode stacking machine, Jelly roll winding machine, tab welders, pouch formers, Formation equipment, etc.
- Experience working with machine suppliers to design or modify pilot or production equipment.
- Proficiency in analyzing and optimizing manufacturing processes using failure mode and effects analysis, root cause analysis, and statistical process control methods such as DOE, 6 sigma, Cp and Cpk, GRR, FMEA, PFMEA, JMP Minitab.
- Familiar with regulatory requirements for battery manufacturing including ISO and automotive standards.
- Experience in electrochemical characterization techniques such as EIS, CV, cycling.
- Knowledge of cleanroom operations.
- Experience with AutoCAD, Solidworks, CATIA or similar CAD software.
- Strong verbal, written, interpersonal and organizational skills.
- Appreciation for and adherence to lab and work safety policies.
- Physical ability to stand, walk, reach, push, pull, and lift.
- Pass a respirator fit test and wear a respirator periodically.
- Participation in 24/7 manufacturing support during critical process implementations.
- Occasional travel to supplier facilities and partner locations (10-20%).
Benefits & Perks
Salary range of $175,000 to $230,000 USD
Manufacturing and lab environments with exposure to specialized atmosphere controls
Occasional travel to supplier facilities and partner locations (10-20%)
Participation in 24/7 manufacturing support during critical process implementations
Full-time schedule, Monday to Friday
Ready to Apply?
Join Blue Current and make an impact in renewable energy
Stay Updated on Sustainability Jobs
Get the latest renewable energy jobs and career tips delivered to your inbox.
Job Alerts
Get notified about new sustainability jobs
More jobs at Blue Current
Battery Manufacturing Technician
Blue Current
Hayward
Full Time
Dec 13
Staff Battery Scientist Cathode
Blue Current
Hayward
Full Time
Nov 8
Temp R D Technician
Blue Current
Hayward
Full Time
Nov 8