Senior Cell Assembly Engineer

Position Summary

The Senior Cell Assembly Engineer is responsible for developing and refining the cell assembly processes at the core of Blue Current's solid-state battery technology, where the novelty of the cell design and formulation means that innovation is a routine part of the job rather than an exception. This engineer owns the assembly process from receipt of dry electrode rolls through finished cell delivery, defining the tooling requirements that mechanical and equipment engineers build to, and applying a sophisticated quality toolkit (visual inspection, layer alignment and tolerancing, X-ray imaging, and electrochemical characterization) to ensure that every cell meets defined structural and performance standards. Working across electrode process, cell engineering, mechanical engineering, and quality teams, the Senior Cell Assembly Engineer is a central integration point where materials, processes, and measurements come together. Success means a cell assembly process that produces high-quality, well-characterized cells consistently today, with the process understanding in place to support scale-up.

Essential Functions & Responsibilities

• Develops and refines cell assembly processes for solid-state batteries, including electrode handling and punching, alignment, lamination, stacking multiple layers, sealing pouches and tabs, and delivering finished products to the cell test team
• Defines tooling and fixture requirements for cell assembly operations, working closely with mechanical and equipment engineers to specify, validate, and iterate on tooling that meets process needs
• Characterizes assembly process parameters and their relationship to cell structural and electrochemical outcomes, building the process understanding needed to set specifications and improve yield
• Applies advanced metrology techniques including X-ray imaging, electrochemical characterization, and electrochemical testing to evaluate assembly quality and diagnose process failures
• Develops and monitors assembly-stage QA/QC protocols in partnership with the Quality team, including visual inspection criteria, edge alignment and layer tolerancing standards, and acceptance criteria for finished cells
• Leads root cause investigations on assembly defects and cell failures attributable to assembly process, implementing and documenting corrective actions
• Collaborates with electrode process and cell engineering teams to ensure assembly process decisions account for upstream material and electrode constraints and downstream cell performance requirements
• Contributes to scale-up planning by identifying critical assembly process parameters and tooling requirements that must be addressed on the path to high-volume manufacturing
• Leads projects by developing clear, actionable plans with defined milestones and success metrics, managing timelines effectively, and ensuring high-quality, on-schedule execution.
• Supports a strong safety culture by following and improving laboratory safety practices, demonstrating exemplary experimental techniques, and helping implement best-practice updates.
• Other duties as assigned, consistent with the scope and level of this position

Minimum Qualifications

Education

• PhD, MS (with 3+ years of relevant experience), or BS (with 5+ years of relevant experience) in Materials Science, Chemical Engineering, Chemistry, Physics, or a related field, with a focus on batteries or electrochemical devices

Experience

• Experience troubleshooting and diagnosing assembly-related failures using advanced characterization techniques such as X-ray imaging or electrochemical impedance spectroscopy, going beyond visual inspection to identify root causes
• Experience translating process requirements into tooling or fixture specifications, and working iteratively with engineers to validate that the resulting hardware meets process needs

Skills & Knowledge

• Sufficient understanding of solid-state or lithium-ion battery electrochemistry to interpret characterization data in the context of assembly process decisions
• Ability to design experiments, analyze results, and draw data-driven conclusions in the absence of established reference points
• Ability to communicate process findings and recommendations clearly to colleagues across engineering, quality, and management functions

Certifications / Licenses

• N/A

Preferred Qualifications

• Hands-on experience with the full assembly sequence or meaningful portions of it, including electrode handling, lamination, layer stacking, and pouch sealing, with personal accountability for process outcomes rather than execution within a defined SOP
• Prior experience with solid-state battery assembly specifically, including familiarity with the unique challenges of handling and assembling solid-state electrodes
• Experience with dry room or controlled environment assembly processes, including familiarity with the operational constraints and material handling requirements those environments impose
• Familiarity with designing and using manual assembly tooling, and then translating learnings to automated or semi-automated assembly equipment. This should include experience contributing to equipment specification or process transfer from manual to automated operations
• Experience contributing to cell assembly scale-up efforts, including identifying critical process parameters and documenting process knowledge in a form that supports future manufacturing transfer
• Background in structured problem-solving methodologies such as PFMEA, with experience applying them to novel or poorly-characterized processes
• Experience working with manufacturing execution systems (MES) or similar production data platforms, including participation in their development or implementation

Core Values — Minimum Qualifications

Physical Requirements & Working Conditions

• Able to pass a respirator fit test and wear a respirator periodically.
• Regularly works in an active manufacturing and laboratory environment; standing and walking for a significant portion of the workday (approximately 4-6 hours per day)
• Frequent interaction with process equipment, requiring manual dexterity and the ability to make detailed visual inspections of materials and coated electrodes
• Occasional lifting of items up to 30 lbs (e.g., material containers, equipment components)
• Prolonged periods of screen-based work for data analysis, documentation, and communication
• Regular use of personal protective equipment (PPE) including safety glasses, gloves, and lab coat; additional PPE may be required depending on materials handled
• Travel is estimated at less than 10% of working time. Overseas travel is possible in the event of FAT program execution or in the event of vendor or supplier visits.