Formation Process Engineer

Factorial is seeking an experienced Formation Process Engineer to lead the development, optimization, and mass-production support of lithium-ion battery formation (Formation) and grading (Capacity Sorting) processes for consumer electronics applications. This role covers the full process lifecycle — from R&D validation through pilot scale-up to high-volume manufacturing — with a focus on maximizing initial Coulombic efficiency (ICE), capacity consistency, and cycle life. The ideal candidate will bring a strong electrochemical engineering background, cross-functional collaboration skills, and a data-driven approach to process improvement and equipment innovation. • Lead the development and parameter optimization of formation protocols for consumer lithium-ion cells (cylindrical, pouch, and prismatic), including pre-formation, standard formation, and step-charge strategies. • Design and validate optimal formation recipes (charge/discharge C-rates, temperature windows, cutoff conditions) to maximize initial Coulombic efficiency (ICE) and SEI film uniformity. • Establish capacity grading (sorting) specifications, defining key binning parameters including capacity, DC internal resistance (DCIR), and self-discharge rate. • Develop product-specific formation programs tailored to varying cell chemistries and consumer device requirements (high energy density, high rate, or long cycle life). • Identify root causes of formation and grading anomalies — including low capacity, high impedance, abnormal voltage plateaus, and lithium plating — and implement effective corrective and preventive actions (CAPA). • Apply SPC, DOE, and FMEA methodologies to reduce batch-to-batch variation and continuously improve process capability (Cpk). • Partner with QA/QE to define inspection standards (IQC/IPQC/OQC) for the formation segment, ensuring outgoing quality meets customer requirements. • Analyze field return failure modes and author 8D reports to support technical customer response. • Optimize formation line takt time and equipment overall equipment effectiveness (OEE), reducing energy consumption per cell and WIP inventory. • Drive process transfers across all development stages: lab bench → pilot line → mass production, including process reviews, first article inspections, and Measurement System Analysis (MSA). • Develop and maintain preventive maintenance (PM) plans for formation equipment to minimize unplanned downtime and ensure line continuity. • Advance automation of cell loading/unloading, in-line voltage/temperature monitoring, and MES data integration to improve smart manufacturing capabilities. • Collaborate with formation cycler suppliers to define next-generation equipment specifications, covering high-precision current control, independent multi-channel testing, and temperature regulation accuracy. • Lead FAT/SAT acceptance testing for formation equipment and establish OQ/PQ qualification protocols. • Evaluate and introduce advanced in-situ measurement technologies (e.g., online EIS, gas evolution detection) to enhance process visibility and control.

• 3+ years of hands-on experience in lithium-ion battery formation and capacity grading processes; background in consumer battery (TWS, mobile, wearable) mass production lines strongly preferred. • Deep understanding of formation fundamentals: SEI layer formation, gas evolution behavior, lithium deposition suppression, and electrolyte decomposition reactions. • Proficiency in DOE, SPC, FMEA, and Six Sigma methodologies; Green Belt or Black Belt certification is a plus. • Demonstrated experience in process transfer from R&D to high-volume manufacturing; familiarity with PPAP/APQP workflows. • Familiarity with major formation cycler platforms (e.g., Neware, Landt, Arbin, Basytec) and their programming logic; ability to independently troubleshoot equipment faults. • Proficiency in electrochemical testing techniques: EIS, DCIR, self-discharge, and battery analysis software (BTS, Arbin, etc.). • Skilled in JMP, Minitab, Python, or Excel for large-scale data analysis and visualization; ability to extract actionable process insights from manufacturing data. • Bachelor's degree or above in Chemical Engineering, Materials Science, Electrochemistry, or a related field (Master's preferred). • Strong cross-functional communication skills; ability to author technical reports and engage in technical discussions with domestic and international customers.