Battery Life Model Development And Analysis Engineer, Ford Energy

Ford Energy is a newly formed, wholly-owned subsidiary of Ford Motor Company dedicated to accelerating U.S. energy independence. Leveraging Ford's century of manufacturing excellence and world-class battery energy storage systems (BESS) technology, Ford Energy designs, manufactures, and services grid-scale and commercial DC battery energy storage systems (BESS). Ford Energy is uniquely positioned to capture the growing demand for reliable, US-built energy storage systems. We are not just building batteries; we are building the infrastructure for the next generation of the American grid.

Why Ford Energy?

At Ford Energy, you have the backing of an industrial manufacturing powerhouse with the agility of a dedicated energy startup offering industry leading technology. We offer a competitive compensation package including performance-based bonuses, Ford vehicle discounts, and the opportunity to shape the energy strategy of one of the world's most iconic brands. Learn more at https://fordenergy.com.

In this position...

The Battery Cell Simulation Engineer is responsible for developing and applying advanced electrochemical models (P2D/P4D) to understand battery cell performance, degradation, and lifetime behavior, with direct linkage to system-level life prediction for Battery Energy Storage Systems (BESS).

This role builds physics-based cell models to quantify degradation mechanisms and translate them into system-level life simulation inputs, enabling accurate warranty estimation and augmentation strategies. The position acts as a key bridge between cell-level electrochemistry and BESS system performance, supporting data-driven decisions on durability, reliability, and lifecycle cost optimization.

About Ford Energy Ford Energy is a newly formed, wholly owned subsidiary of Ford Motor Company dedicated to accelerating US energy independence. Leveraging Ford's century of manufacturing excellence and world-class battery energy storage systems (BESS) technology, Ford Energy designs, manufactures, and services grid-scale and commercial DC battery energy storage systems (BESS). Ford Energy is uniquely positioned to capture the growing demand for reliable, US-built energy storage systems. We are not just building batteries; we are building the infrastructure for the next generation of the American grid.

What you'll do...

• Electrochemical Modeling (Primary Focus)

• Develop and apply high-fidelity electrochemical models, including P2D/P4D lithium-ion battery models and reduced-order models for system integration.

• Simulate reaction kinetics and transport phenomena, lithium concentration gradients and overpotential, and internal current density and utilization distribution.

• Evaluate cell capability limits, including power and energy capability, SOC-dependent performance, and rate limitations under different conditions.

• Cell-Level Life & Degradation Modeling

• Develop physics-based models to predict cell degradation, including SEI growth and side reactions, lithium plating risk and conditions, and loss of active material and impedance growth.

• Quantify capacity fade and resistance increase over life, and sensitivity to temperature, SOC window, and cycling conditions.

• Support cell design trade-offs and degradation mitigation strategies.

• Thermal-Electrochemical Coupling

• Develop coupled electrochemical-thermal models, including heat generation from electrochemical reactions and temperature-dependent kinetics and degradation.

• Analyze cell temperature gradients and hot spots, and thermal impact on performance and aging.

• Provide heat generation and degradation sensitivity inputs for system-level modeling.

• Manufacturing Variation & Cell Behavior

• Incorporate manufacturing-induced variations into cell models, including electrode thickness and loading variation, porosity and density variation from calendaring, and microstructural heterogeneity.

• Evaluate impact of process variation on performance distribution, and manufacturing defects on degradation and life.

• Support translation of modeling insights into process control targets and cell consistency and quality improvements.

• System-Level Life Modeling Interface (BESS Integration)

• Translate cell-level model outputs into system-level inputs for BESS simulations, including degradation rates under varying duty cycles and temperature and usage sensitivities.

• Support development of system-level life prediction models and duty cycle-based aging simulations.

• Collaborate with system and CAE teams to ensure consistent model integration and proper scaling from cell to pack to system.

• Warranty Estimation & Augmentation Strategy Support

• Provide modeling inputs for warranty projections (capacity retention, degradation limits) and performance degradation over service life.

• Support evaluation of BESS augmentation strategies (e.g., module replacement, capacity add-back) and trade-offs between degradation, performance, and cost.

• Enable data-driven decisions on lifecycle management and total cost of ownership (TCO).

• Model Calibration & Validation

• Calibrate models using experimental data, including cycling and aging tests, and EIS, rate capability, and thermal data.

• Validate performance and degradation predictions vs. test data.

• Conduct sensitivity analysis, parameter estimation, and uncertainty quantification.

• Cross-Functional Collaboration

• Work closely with the Ford Battery Modeling Team and BESS system and controls teams.

• Support external suppliers with model alignment and parameterization.

• Translate detailed electrochemical insights into system-level engineering decisions.

What you'll do...

• Electrochemical Modeling (Primary Focus)

• Develop and apply high-fidelity electrochemical models, including P2D/P4D lithium-ion battery models and reduced-order models for system integration.

• Simulate reaction kinetics and transport phenomena, lithium concentration gradients and overpotential, and internal current density and utilization distribution.

• Evaluate cell capability limits, including power and energy capability, SOC-dependent performance, and rate limitations under different conditions.

• Cell-Level Life & Degradation Modeling

• Develop physics-based models to predict cell degradation, including SEI growth and side reactions, lithium plating risk and conditions, and loss of active material and impedance growth.

• Quantify capacity fade and resistance increase over life, and sensitivity to temperature, SOC window, and cycling conditions.

• Support cell design trade-offs and degradation mitigation strategies.

• Thermal-Electrochemical Coupling

• Develop coupled electrochemical-thermal models, including heat generation from electrochemical reactions and temperature-dependent kinetics and degradation.

• Analyze cell temperature gradients and hot spots, and thermal impact on performance and aging.

• Provide heat generation and degradation sensitivity inputs for system-level modeling.

• Manufacturing Variation & Cell Behavior

• Incorporate manufacturing-induced variations into cell models, including electrode thickness and loading variation, porosity and density variation from calendaring, and microstructural heterogeneity.

• Evaluate impact of process variation on performance distribution, and manufacturing defects on degradation and life.

• Support translation of modeling insights into process control targets and cell consistency and quality improvements.

• System-Level Life Modeling Interface (BESS Integration)

• Translate cell-level model outputs into system-level inputs for BESS simulations, including degradation rates under varying duty cycles and temperature and usage sensitivities.

• Support development of system-level life prediction models and duty cycle-based aging simulations.

• Collaborate with system and CAE teams to ensure consistent model integration and proper scaling from cell to pack to system.

• Warranty Estimation & Augmentation Strategy Support

• Provide modeling inputs for warranty projections (capacity retention, degradation limits) and performance degradation over service life.

• Support evaluation of BESS augmentation strategies (e.g., module replacement, capacity add-back) and trade-offs between degradation, performance, and cost.

• Enable data-driven decisions on lifecycle management and total cost of ownership (TCO).

• Model Calibration & Validation

• Calibrate models using experimental data, including cycling and aging tests, and EIS, rate capability, and thermal data.

• Validate performance and degradation predictions vs. test data.

• Conduct sensitivity analysis, parameter estimation, and uncertainty quantification.

• Cross-Functional Collaboration

• Work closely with the Ford Battery Modeling Team and BESS system and controls teams.

• Support external suppliers with model alignment and parameterization.

• Translate detailed electrochemical insights into system-level engineering decisions.