Cell DV/PV Testing Engineer, Ford Energy

Ford Motor Company•Dearborn, MI

1h•$74,300 - $166,200•Hybrid

About The Position

The Battery Cell DV/PV Testing Engineer executes design verification (DV) and process verification (PV) testing on battery cells used in Ford Energy’s battery energy storage systems, with a primary focus on cell performance and life characterization. The role includes hands-on internal DV/PV testing, tracking and analyzing performance and life tests conducted by external cell suppliers, and diagnosing cell-level failures through teardown and root-cause analysis. It also provides direct support to production teams during PV builds. The engineer operates cell-level test equipment, develops and executes DVP&R/PVP&R test plans, interprets test data, and supports cell failure diagnosis and teardown analysis. The role contributes to evaluation of future cell chemistries for BESS applications and works with cell design, pack integration, BMS, quality, supplier engineering, production, and R&D teams to ensure cells meet performance, life, and reliability requirements before and during production ramp. The position is based in Dearborn, Michigan, and is hybrid, with a requirement to be onsite four or more days per week. The work may take place in office, laboratory, manufacturing, or supplier environments, with occasional work in high-voltage or industrial environments using appropriate training and PPE. Occasional travel to supplier, manufacturing, laboratory, or customer sites may be required. The role is initially employed by Ford and is expected to transition to its wholly owned BESS subsidiary within one year. Visa sponsorship is not available.

Requirements

Bachelor’s degree in Electrical, Chemical, Mechanical, Materials, or a related engineering discipline.
At least 3 years of experience testing battery cells or battery systems in a laboratory or validation environment.
Hands-on experience setting up and operating battery cyclers, environmental or thermal chambers, and data acquisition systems.
Working knowledge of DV/PV testing methodology and DVP&R/PVP&R documentation, with a grounding in cell performance and life test methods.
Experience or working knowledge of battery-cell failure analysis and teardown techniques, including mechanical disassembly, visual or optical inspection, and electrical characterization.
Experience tracking or analyzing test results generated by external suppliers or test labs.
Ability to read and interpret test specifications, engineering drawings, and cell datasheets.
Strong data-analysis skills using Excel and/or MATLAB/Python, and clear technical report-writing skills.
Ability and willingness to work in a laboratory environment with battery test articles while following required PPE and safety protocols.
Ability and willingness to travel occasionally to supplier or external test-lab sites.
Legally authorized to work in the United States; employment eligibility verification is required at hire.

Nice To Haves

Master’s degree in Electrical, Chemical, or Materials Engineering.
Experience with LFP or sodium-ion cell chemistries and their performance and life behavior.
Experience performing cell teardown and failure analysis, including SEM, XRD, CT scanning, or similar diagnostic tools, directly or through coordination with a materials or failure-analysis laboratory.
Experience supporting production teams during PV builds, including real-time troubleshooting and non-conformance resolution.
Exposure to evaluating or developing next-generation or alternative cell chemistries for energy storage applications.
Experience supporting cell supplier qualification, including review of DFMEA/PFMEA, control plans, and PPAP documentation.
Experience in the BESS, EV, or stationary storage industry.
Six Sigma, IATF 16949, or ISO 17025 laboratory quality experience.
Experience correlating cell-level performance and life data and failure analysis to module- or pack-level performance outcomes.
Experience with DV/PV test execution and DVP&R/PVP&R documentation.
Experience with cell performance and life characterization, including capacity, impedance/DCIR, rate/power, cycle life, and calendar life.
Experience setting up and operating battery cyclers and environmental or thermal chambers.
Experience with supplier test tracking and results analysis.
Experience investigating degradation trends and out-of-spec results.
Experience with test-data reduction and technical reporting.
Experience coordinating across design, quality, and supplier engineering teams.

Responsibilities

Execute internal DV and PV test plans (DVP&R/PVP&R) on battery cells, focusing on capacity, impedance/DCIR, rate and power performance, cycle life, calendar life, and coulombic efficiency.
Set up and operate battery cyclers, environmental and thermal chambers, and data acquisition systems to generate cell performance and life data.
Support supplementary environmental testing, including thermal cycling, vibration, and shock, in coordination with test labs or engineering teams.
Track external supplier cell-test program status and schedules, ensuring alignment with internal DV/PV requirements and program timelines.
Collect and analyze supplier-generated test results; compare them with internal requirements, internal test data, and prior supplier lots to identify gaps, trends, and discrepancies.
Coordinate with supplier engineering contacts to clarify test methods, request missing data, and follow up on issues or anomalies.
Support review of supplier quality documentation, including DFMEA/PFMEA, control plans, and PPAP, as it relates to cell performance and life testing.
Summarize supplier test outcomes for cell design, quality, and program teams, and flag risks to supplier qualification or sourcing decisions.
Diagnose cell-level failures and anomalies from DV/PV testing, field returns, or production builds using structured root-cause methods such as 8D, fishbone/Ishikawa, and 5-Why.
Plan and perform teardown analysis of failed or suspect cells, including mechanical disassembly, visual and optical inspection, and electrical characterization; coordinate with materials science or failure-analysis labs for techniques such as SEM, XRD, and CT scanning as needed.
Document teardown findings, failure modes, and probable root causes in traceable reports; recommend and track corrective and preventive actions.
Build and maintain a failure-mode knowledge base to support diagnosis of recurring or similar issues.
Collect, reduce, and analyze internal, supplier, and teardown/diagnostic data; identify anomalies, degradation trends, and out-of-spec conditions, and document findings in traceable test reports.
Maintain test traceability to requirements, test-method documentation, and calibration records.
Communicate test status, results, diagnostic findings, and risks to cell design, pack integration, BMS, and quality engineering teams; support design, supplier readiness, PV readiness, and program gate reviews.
Recommend improvements to test methods and data-analysis processes to improve efficiency, repeatability, and data quality.
Support evaluation, screening, and characterization of next-generation and alternative cell chemistries, including LFP and sodium-ion, for future BESS programs.
Develop and execute test plans and diagnostic protocols for new chemistries, gathering performance, life, and failure-mode data to inform chemistry selection and readiness decisions.
Collaborate with cell design and R&D teams to translate teardown and diagnostic learnings into chemistry and cell-design improvement recommendations.
Stay informed about emerging cell chemistry trends and failure mechanisms relevant to stationary storage and share insights with the engineering team.
Support production teams during PV builds, including real-time troubleshooting and non-conformance resolution when needed.

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 related family-care benefits.
Adoption and surrogacy expense reimbursement, fertility treatments, and other family-building benefits.
Vehicle discount program for employees and family members, and management leases.
Tuition assistance.
Employee resource groups.
Paid time off for individual and team community service.
Paid holidays, including the week between Christmas and New Year’s Day.
Paid time off and the option to purchase additional vacation time.
Competitive compensation package including performance-based bonuses.
Ford vehicle discounts.