Staff Engineer, Process Development
Confirmed on the employer's own hiring board on Oct 15, 2026. First seen by Alion on Oct 12, 2026. CelLink scores A on the Alion truth index.
Position Summary
This position leads the development, optimization, scale-up, and industrialization of manufacturing processes involving coatings, films, polymers, plastics, laminations, and adhesive or thermally activated bonding systems. The role applies chemical engineering fundamentals, thermodynamics, heat transfer, material science, and structured experimentation to establish robust, repeatable production processes and transfer them successfully into manufacturing. The Staff Engineer, Process Development and their small, focused team of 3-4 Engineers and Techs partners closely with R&D/Product Engineering, Process Engineering, Equipment Engineering, Automation & Controls, Quality, Operations, and suppliers to move technologies from concept and pilot development through qualification and production release.
Essential Duties & Responsibilities
- Lead development, optimization, scale-up, qualification, and production release of roll-to-roll and other material-conversion processes involving coatings, films, polymers, plastics, laminations, patterning and adhesive or thermally activated bonding systems; translate material and product requirements into scalable manufacturing processes.
- Apply thermodynamics, heat transfer, adhesion science, web handling, tension control, and material behavior to characterize the relationship among temperature, pressure, dwell time, line speed, web tension/alignment, material chemistry, surface condition, equipment behavior, and finished-product performance; establish robust process windows and critical process parameters.
- Design and execute structured experiments, including DOE and statistical analysis, to evaluate materials, formulations, equipment, and process conditions; troubleshoot complex coating, bonding, delamination, curing, thermal, and material-related failures and drive permanent corrective actions.
- Partner with R&D/Product Engineering, Process Engineering, Equipment Engineering, Automation & Controls, Quality, Operations, and suppliers to define equipment and control requirements, complete engineering trials and validations, and transfer new processes into stable high-volume manufacturing.
- Maintain a clean and orderly work area; follow prescribed safety and environmental regulations.
- Demonstrate CelLink’s culture of integrity, teamwork, self-discipline, and professional competence; perform other duties as assigned.
Minimum Qualifications
- Bachelor's degree in Chemical Engineering, Materials Science or Engineering, Polymer Engineering, Chemistry, Mechanical Engineering, or a related technical discipline.
- 7+ years of relevant engineering experience in process development, manufacturing engineering, materials engineering, or a related role, including experience scaling processes from development or pilot scale into production.
- Demonstrated experience with coatings, films, polymers, plastics, laminates, adhesive bonding, film converting, and thermally activated adhesive systems, with strong working knowledge of thermodynamics, heat transfer, and temperature-dependent material behavior.
Preferred Qualifications
- Master's degree or Ph.D. in Chemical Engineering, Materials Science, Polymer Science, Chemistry, or a related discipline.
- Hands-on experience with roll-to-roll or web-based process development, including web handling/tension control, coating or adhesive application, lamination, thermal bonding/curing, and process scale-up in high-volume or automated manufacturing.
- Knowledge of polymer rheology, adhesion science, surface energy, thermal conductivity, thermal expansion, temperature mapping/profiling, and material characterization.
Knowledge, Skills & Abilities
- Strong experimental design, data analysis, structured problem-solving, and root-cause analysis skills; able to connect material properties, thermal behavior, equipment conditions, and process variables to manufacturing performance.
- Hands-on technical leadership with strong cross-functional communication and influencing skills; comfortable making sound decisions with incomplete information and balancing technical rigor with the speed required in a rapidly scaling manufacturing environment.
Working Conditions / Hours / Physical Requirements
The employee’s primary workspace will be located on the manufacturing floor, requiring daily, hands-on engagement with manufacturing processes, equipment, and operations. During the workday, the employee regularly moves throughout a large manufacturing facility and may stand or walk for extended periods. The role may also require climbing stairs, bending, reaching, crouching, kneeling, or working in varied positions while observing operations, troubleshooting issues, supporting employees, or interacting with equipment.
The manufacturing environment includes exposure to operating machinery, moving mechanical parts, elevated noise, nuisance dust, and common industrial chemicals. Appropriate PPE is provided and required where applicable. The employee may occasionally lift and/or move up to 35 pounds independently or up to 50 pounds with assistance.
May require extended hours, nights, weekends, holidays, or off-shift support based on business needs. Travel to other CelLink sites, suppliers, vendors, integrators, customers, or training locations may be required.
Direct Reports
Process Development engineers and/or technical staff as assigned.
We believe diversity and inclusion among our teammates are essential to our success. We celebrate diversity and are committed to creating an inclusive environment for all employees while building teams that represent a variety of backgrounds, perspectives, and skills. We are an equal opportunity employer. All employment is decided based on qualifications, merit, and business needs. CelLink participates in the E-Verify program in specific locations as required by law.
CelLink was founded in 2012 and entered volume production in 2018. CelLink provides electrical systems to the world's leading automotive OEMs & EV manufacturers, data center developers, and stationary power companies. The company has raised approximately $315M in funding through private investment and multiple grants from the US Department of Energy. CelLink’s investors include 3M, Atreides, BMW, BorgWarner, Bosch, D1 Capital, Fidelity, Fontinalis Partners, Ford, Franklin Templeton, Lear, Park West, SK Telecom, Standard Investments, T. Rowe Price, Tinicum, and Whale Rock.