Formation Process Engineer - 3C Battery

Factorial Energy is seeking a Formation Process Engineer to join our team in our Cheonan, South Korea location. This person will be responsible for the development, optimization, and mass-production support of formation and grading processes for our Silicon Power Cell line. This role covers the full formation lifecycle — from R&D validation through pilot scale-up to high-volume manufacturing — with a focus on silicon anode-specific formation protocol development, SEI stability, and high-rate capability optimization. The ideal candidate brings deep electrochemical engineering expertise , hands-on formation equipment experience, and a data-driven approach to process improvement and yield stabilization. • Lead development and optimization of formation protocols for Si-based power cells, including pre-formation, standard formation, and step-charge strategies tailored to silicon anode expansion behavior • Design and validate formation recipes (charge/discharge C-rates, temperature windows, cutoff conditions) to maximize ICE, SEI film uniformity, and suppress lithium plating risk on high-Si anodes • Establish capacity grading specifications defining key binning parameters including capacity, DCIR, and self-discharge rate • Develop product-specific formation programs optimized for high-rate power cell requirements • Develop formation protocols that account for silicon anode volume expansion during initial lithiation, minimizing mechanical stress and SEI instability • Collaborate with R&D and electrode teams to correlate formation conditions with Si anode first-cycle efficiency, swelling behavior, and long-term cycle stability • Identify root causes of formation and grading anomalies and implement CAPA actions • Apply SPC, DOE, and FMEA methodologies to reduce batch-to-batch variation and improve process capability ( Cpk ) • Partner with QA/QE to define inspection standards for the formation segment • Optimize formation line takt time and OEE, reducing energy consumption per cell and WIP inventory • Drive process transfers across all development stages: lab bench → pilot line → mass production • Develop and maintain PM plans for formation equipment to minimize unplanned downtime • Collaborate with formation cycler suppliers to define equipment specifications • Lead FAT/SAT acceptance testing for formation equipment and establish OQ/PQ qualification protocols • Support MES data integration and in-line monitoring for smart manufacturing capabilities

• Have 3+ years of hands-on experience in lithium-ion battery formation and grading processes • Have experience with silicon anode or high-energy-density cell formation preferred • Have led or substantially contributed to at least one full NPI or mass production ramp-up project • Have deep understanding of formation fundamentals: SEI formation, gas evolution, lithium deposition suppression, and electrolyte decomposition • Are familiar with major formation cycler platforms (Neware, Landt, Arbin, Basytec) and can independently troubleshoot equipment faults • Are proficient in electrochemical testing: EIS, DCIR, self-discharge, and battery analysis software • Are proficient in DOE, SPC, FMEA, and data analysis tools (JMP, Minitab, Python, or Excel) • Have experience with MES/ERP data extraction and visualization • Hold a Bachelor's degree or higher in Chemical Engineering, Materials Science, Electrochemistry, or related field; Master's preferred • Have experience with Si anode formation protocol development or high-rate power cell formation (preferred) • Are familiar with consumer battery safety standards (IEC 62133, UL 1642, UN 38.3) (preferred)