Battery Life Model Development and Analysis Engineer, Ford Energy

Ford Motor Company • Dearborn, MI

11d • $74,300 - $166,200 • Hybrid

About The 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.

Requirements

• Bachelor's degree in Chemical Engineering, Mechanical Engineering, Materials Science, Physics, or related field.
• 3+ years (MS) or 5+ years (BS) of experience in battery modeling or related fields.
• Strong expertise in electrochemical modeling (P2D or equivalent) and lithium-ion battery fundamentals.
• Simulation tools: COMSOL Multiphysics or equivalent.
• Programming: Python, MATLAB.
• Strong knowledge of electrochemical systems and transport phenomena, battery degradation mechanisms, and thermal effects in battery cells.
• Electrochemical Modeling Depth — expertise in P2D/P4D and physical interpretation.
• Degradation & Life Prediction — strong understanding of aging mechanisms and lifetime modeling.
• Cell-to-System Translation — ability to convert cell physics into system-level life predictions.
• Multiphysics Integration — electrochemical-thermal coupling capability.
• Analytical Problem Solving — identifies drivers of degradation and performance variation.
• Collaboration — works across cell, system, and CAE teams.
• Communication — translates complex models into actionable insights.

Nice To Haves

• Master's or PhD in relevant discipline.
• Experience with P2D/P4D electrochemical models and battery degradation and life modeling.
• Familiarity with system-level battery life modeling (BESS or EV) and warranty or lifecycle analysis.
• Understanding of thermal-electrochemical coupling and battery cell manufacturing effects.

Responsibilities

• 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.
• 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.
• 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.
• 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.
• 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.
• 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).
• 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.
• 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.

Benefits

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time.
• performance-based bonuses
• Ford vehicle discounts

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level