Senior Electrode Process Engineer

Position Summary

The Senior Electrode Process Engineer is responsible for producing finished electrodes that meet the quality and performance standards required by Blue Current's cell assembly team, while simultaneously developing the process knowledge needed to scale electrode manufacturing to high-volume production. This role covers the full electrode manufacturing process from slurry preparation through coating, drying, and calendering, with an emphasis on process characterization, yield improvement, and the establishment of robust QA/QC protocols developed in partnership with the Quality team. The Senior Electrode Process Engineer plays a central role in validating processes at current scale and defining the pathway to gigafactory-level production, ensuring that what works in the lab or pilot line is understood well enough to translate reliably at volume. Success means consistent, high-quality electrode delivery to the cell assembly team today, and a process foundation that is ready to scale tomorrow.

Essential Functions & Responsibilities

• Executes and refines electrode manufacturing processes across all unit operations including slurry mixing, coating, drying, and calendering, delivering finished electrodes to the cell assembly team that consistently meet defined quality specifications
• Evaluates, selects, and validates process equipment based on the specific rheological, chemical, and dimensional requirements of each electrode formulation. Examples may include selecting/validating mixer types (e.g., planetary, ball mill, homogenizer) and coating methods (e.g., slot die, comma, gravure).
• Characterizes process parameters and their relationships to electrode properties, building the process understanding needed to set specifications, tighten tolerances, and improve yield
• Develops and monitors QA/QC protocols in partnership with the Quality team, including inline and post-process inspection criteria, measurement methods, and acceptance standards for finished electrodes
• Identifies process failure modes and leads root cause investigations, implementing corrective actions and documenting outcomes to build institutional process knowledge
• Translates current pilot-scale process knowledge into scalable procedures, identifying critical process parameters and equipment requirements that must be addressed on the path to high-volume manufacturing
• Collaborates with cell engineering and materials teams to ensure electrode process decisions account for downstream cell assembly requirements and cell performance outcomes
• 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

• Hands-on experience developing and optimizing slurry-based electrode manufacturing processes, including mixing, coating, drying, and calendering operations
• Track record of selecting and validating process equipment for a given set of material and process requirements, with working knowledge of multiple mixer and coater types
• Experience developing or operating QA/QC protocols in a manufacturing or process development environment, including defining specifications and measurement methods
• Experience working across functional teams, communicating process findings and recommendations to colleagues in adjacent disciplines such as cell engineering or materials science

Skills & Knowledge

• Working knowledge of slurry rheology and how mixing and coating process parameters influence electrode microstructure and final properties
• Proficiency with standard data analysis tools sufficient to process, visualize, and communicate process and quality data

Certifications / Licenses

• N/A

Preferred Qualifications

• Prior experience with solid-state or dry electrode manufacturing processes, including solvent-free or low-solvent coating approaches
• Familiarity with lithium-ion or solid-state battery cell architecture and how electrode properties such as porosity, loading, and thickness influence cell performance
• Experience contributing to process scale-up efforts, including equipment specification, process transfer documentation, or qualification runs at increased volume
• Background in failure analysis or structured problem-solving methodologies such as PFMEA or Six Sigma
• Familiarity with statistical methods for process characterization and control, such as design of experiments or statistical process control
• Familiarity with pilot-to-production process validation frameworks, including process capability studies or equipment qualification protocols
• Experience working with manufacturing execution systems (MES) or similar production tracking and data management 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.