Process Engineer / Sr Engineer / Principal

Job Summary:

We are seeking a Process Engineer to support the development and industrialization of our next generation high energy density Li-ion battery. You will own key cell assembly and packaging processes - developing and qualifying process recipes, defining robust process windows through structured experimentation, and establishing the process controls and inspection methods that sustain quality at volume. Working across engineering functions, you will drive equipment qualification, lead root cause analysis and continuous improvement, and transfer capable processes into high-volume production with strong cycle time, yield and material utilization.

Responsibilities:

• Own degas process - develop and qualify vacuum degas, final seal and trim recipes, optimizing vacuum profile, dwell time, seal temperature/pressure and time to eliminate residual gas, gas pockets and seal defects while protecting cell integrity.
• Develop and qualify liquid dispensing (electrolyte fill) processes - dose accuracy and repeatability, fill volume and weight control, wetting/soak time, vacuum-assisted fill, and dry-room/moisture controls; establish leak, weight-gain and dispense-verification checks.
• Develop and qualify adhesive/glue dispensing processes - needle and jet dispense path programming, bead geometry and volume, dispense pressure and flow rate, viscosity and pot-life control, cure profile, adhesion and bond-strength qualification.
• Characterize and control critical-to-quality parameters across degas, liquid fill and glue dispense, including gauge R&R on dispense weight and vision inspection, SPC limits and Cpk targets for each parameter.
• Work with Equipment Engineering on tool capability, maintenance intervals and consumable life (nozzles, needles, seals, pumps).
• Lead root cause analysis and corrective action for degas, fill and dispense defects - seal leaks, underfill/overfill, electrolyte contamination, glue voids, stringing, skips and squeeze-out - using FMEA and 8D methodologies.
• Support scale-up and transfer of degas, liquid and glue dispensing processes from development to high-volume production, improving cycle time, first-pass yield and material utilization.
• Design and run DOE-based experiments on degas, electrolyte fill and dispense parameters to define process windows and optimize yield against the company technology roadmap.
• Lead and participate in cross-functional teams of process, mechanical, equipment and test engineers to develop process and tooling for next generation cell designs capable of large scale manufacturing.
• Analyze and summarize performance metrics via data analysis tools such as JMP.
• Create and execute on project plans and drive projects to completion on schedule
• Deliver final product, data driven analyses on schedule and effectively communicate the results to various stakeholders
• Create and maintain Work Instructions, OCAP, FMEA and Control Plan documents as per QMS requirements

Qualifications:

• Bachelor’s Degree in Chemical Engineering, Materials Science Engineering, Physics, Chemistry, Mechanical Engineering or related discipline required (7+ years of work experience and/or Master’s and Ph. D preferred)
• Demonstrated capability to effectively analyze process data and extract/summarize meaningful information required
• Demonstrated technical program management skills such as meeting deadlines and milestones as well as excellent communication skills such as summarizing data and writing reports required
• Willingness to travel in future as needed
• Self-motivated and demonstrated ability to work independently and as part of cross-functional teams to solve complex multi-disciplinary problems required
• Familiarity with SPC, DOE, FMEA and 8D methodologies required
• Experience in design, development, and integration of Li-Ion batteries highly desired
• Demonstrated creative and critical thinking ability and attention to detail is highly desired
• Proven track-record of process integration in the scale-up of R&D processes to high-volume manufacturing desired

Good interpersonal skills.