Principal Process Engineer Battery Cell Assembly and Formation
Blue CurrentHayward, California
Full Time
Posted October 29, 2025
$175k - $230k
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Job Description
A Principal Process Engineer responsible for developing and optimizing cell assembly manufacturing processes for solid-state batteries, leading a team, and collaborating on equipment design to improve production reliability, quality, and scalability in a fast-paced, innovative environment.
Key Responsibilities
- Lead the design and development of cell assembly and formation manufacturing processes on the pilot line.
- Provide technical guidance, coaching, and leadership to engineers and technicians.
- Optimize manufacturing parameters to improve performance, yield, and throughput.
- Develop and implement process control strategies and establish process specifications and work instructions.
- Create training materials and train personnel in pilot line cell assembly processes.
- Design and implement statistical process control systems for critical parameters.
- Generate machine specifications and collaborate with suppliers to design or modify equipment.
- Partner with R&D to transition laboratory processes to pilot manufacturing.
- Lead technology transfer activities to contract manufacturers or partner facilities.
- Scale battery production to meet internal and customer 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, preferred.
- 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
Participation in 24/7 manufacturing support during critical process implementations
Physical ability to stand, walk, reach, push, pull, and lift
Pass a respirator fit test and wear a respirator periodically
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