Materials Development Engineer

ADVANCED IONICS•New Berlin, WI

68d•Onsite

About The Position

The Materials Development Engineer is responsible for developing high temperature films, coatings, seals, and production methods for our SymbionTM intermediate-temperature steam electrolyte platform. This role bridges fundamental materials science and electrolyte system integration, ensuring that ceramics, seals and advanced coating perform reliably in a stressful environment with hydrogen and oxygen produced on opposing sides of the cell. You will own materials development across the electrolyzer stack, working directly with electrolyzer technology leadership and cross-functional engineering teams to translate laboratory innovations into scalable, production-ready solutions.

Requirements

Bachelor’s degree in Materials Science, Ceramic Engineering, Chemical Engineering or equivalents.
At least 5 years of experience in designing, developing and quantifying ceramic materials and seals for complex systems, preferably in the high temperature electrolyzer, fuel cell, or adjacent industries.
Strong foundation knowledge of ceramic materials science: Phase diagram, sintering mechanism, thermal expansion, and mechanical properties (flexural strength, fracture toughness and creep resistance).
Glass and glass-ceramic compositions for seal applications.
Microstructure-property relationships; ability to interpret SEM, XRD, and thermal analysis data.
Ability to demonstrate expertise in high temperature seals, including wet seal design, sealing materials (glasses, ceramics, micas, vermiculites, and high temperature polymers) and seal performance metrics (leak rate, compression set, thermal cycling durability).
Proficiency in simulation and testing methodologies: Thermal analysis (DSC, TGA, dilatometry).
Mechanical testing (compression, flexure, thermal shock resistance).
Electrochemical testing (if experience available) or willingness to rapidly develop competency.
Hands-on experience with advanced ceramic processing (tape casting, slip casting, hot-press sintering, or wet coating methods); understanding of scaling challenges (shrinkage, defect propagation, process control).

Nice To Haves

Master’s degree is strongly preferred but not required if equivalent industry experience is demonstrated.
Ability to execute design of experiments (DOE) protocols with robust statistics-backed methods (preferred).
Data science and/or data management experience in a professional setting preferred.

Responsibilities

Design and develop advanced materials for multiple portions of our electrolyzer cell, balancing mechanical strength, thermal stability, electrochemical performance, and manufacturing scalability.
Optimize materials-electrolyte compatibility in working environments; evaluate capillary behavior, wetting properties, and corrosion resistance under thermal cycling and conditions.
Develop production methods and processes of various electrolyzer materials.
Conduct simulations and testing to evaluate the performance of materials and processing methods under various operating conditions.
Drive electrochemical materials integration, collaborating with electrochemist and stack engineering teams to ensure materials contribute to the target performance metrics.
Work with suppliers to source, qualify and optimize raw materials, precursors, and specialized equipment; negotiate technical specifications and pilot production runs.
Develop and maintain comprehensive documentation, including the materials specifications, processing SOPs, failure analysis reports, and IP disclosures related to seals, coatings, and ceramic compositions.
Participate in cross-functional teams to ensure that component designs are integrated effectively with cell architecture, stack sealing strategy and system level performance targets.
Contribute to technology strategy for advanced materials in intermediate-temperature electrolysis, including evaluation of emerging ceramics, glasses, high-temperature polymers, and unconventional processing methods.