Pack Manufacturing Engineer

Forge Nano•Thornton, CO

1d•Onsite

About The Position

Forge Nano is seeking an experienced Pack Manufacturing Engineer to lead development, implementation, and scale-up of its in-house battery pack manufacturing capabilities. Reporting to the EVP of Energy Storage, this hands-on technical manufacturing lead will transform battery pack designs into safe, repeatable, and scalable production processes. The role works directly on the manufacturing floor to establish assembly methods, tooling, fixtures, quality controls, inspection processes, testing protocols, and manufacturing documentation. The engineer will collaborate with Engineering, Quality, EHS, Program Management, and Manufacturing teams to support operational excellence, product quality, and compliance with applicable standards. The role also provides technical leadership and mentorship to battery pack assembly technicians, developing workforce capabilities and reinforcing a culture of safety, quality, and continuous improvement.

Requirements

Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Electrical Engineering, Industrial Engineering, or a related technical field, or an equivalent combination of education and industry background.
At least 5 years in a manufacturing engineering role with significant hands-on involvement in lithium-ion battery module and/or battery pack assembly operations.
Proven success building, troubleshooting, or supporting battery packs in a production or manufacturing environment.
Demonstrated ability to develop manufacturing processes from prototype builds through repeatable production implementation.
Proficiency in creating manufacturing work instructions, process documentation, assembly procedures, and inspection requirements.
Experience training, mentoring, or leading manufacturing technicians and operators.
Strong mechanical aptitude and proficiency with production tools, fixtures, torque equipment, electrical test equipment, and manufacturing systems.
Skill in root cause analysis, corrective actions, and continuous process improvement.
Ability and willingness to spend significant time working directly on the manufacturing floor.
Ability to safely work around manufacturing equipment and battery systems and occasionally move materials and equipment weighing up to 50 pounds, with or without reasonable accommodation.

Nice To Haves

At least 7 years supporting battery module or battery pack manufacturing, EV, aerospace, defense, industrial battery, or other high-reliability manufacturing environments.
Track record of launching, scaling, or transferring battery pack assembly operations between facilities or manufacturing partners.
Familiarity with cylindrical-cell battery pack architectures.
Working knowledge of battery interconnection technologies, including laser welding, resistance welding, ultrasonic welding, and mechanical busbar assembly.
Background in pack-level electrical testing, insulation resistance testing, continuity testing, BMS integration, and end-of-line validation.
Knowledge of PFMEA, APQP, Control Plans, process validation, and manufacturing readiness assessments.
Familiarity with ISO 9001 or similar quality management systems.
Experience manufacturing battery systems for defense, aerospace, automotive, industrial, or other highly regulated industries.
Understanding of battery transportation, safety, and performance standards, including UN 38.3 and relevant IEC, UL, SAE, or customer-specific requirements.

Responsibilities

Lead implementation and scale-up of battery pack assembly operations.
Translate battery pack designs, specifications, drawings, and bills of material into robust manufacturing processes.
Develop assembly sequences for battery cells, modules, busbars, wiring harnesses, BMS components, thermal management systems, enclosures, adhesives, insulation materials, fasteners, and related hardware.
Establish manufacturing methods for fastening, adhesive application, electrical interconnections, welding, BMS integration, pack closure, and final testing.
Identify, specify, and support procurement of manufacturing equipment, fixtures, tooling, gauges, safety equipment, and test systems.
Support pilot builds and transition prototype assembly processes into repeatable low-volume production operations.
Lead manufacturing readiness activities for new battery pack designs and production launches.
Participate in battery pack builds and demonstrate best-practice assembly methods to production personnel.
Identify manufacturing risks and develop mitigation plans before production builds begin.
Troubleshoot manufacturing issues and lead structured root cause analysis and corrective action activities.
Participate in DFM and DFA reviews, providing production-focused feedback to engineering teams.
Partner with suppliers and external manufacturing partners to transfer battery pack manufacturing knowledge and best practices.
Develop manufacturing plans, schedules, milestones, and deliverables in collaboration with Program and Project Managers.
Establish in-process inspections, acceptance criteria, traceability requirements, and manufacturing control plans.
Partner with the QMS team to develop manufacturing documentation, process controls, and quality standards.
Support process validation, manufacturing readiness reviews, and quality improvement initiatives.
Ensure manufacturing processes meet internal quality standards and applicable customer, industry, and regulatory requirements.
Maintain process documentation, work instructions, inspection procedures, and manufacturing records.
Serve as the primary technical resource for battery pack assembly technicians.
Train and mentor technicians on assembly processes, tooling, equipment operation, workmanship standards, inspection requirements, and manufacturing best practices.
Develop practical, scalable work instructions and provide daily technical guidance and hands-on coaching.
Help build a disciplined manufacturing culture focused on safety, quality, and continuous improvement.
Establish safe manufacturing practices for high-energy lithium-ion battery systems and complete required training to work safely with systems up to 1,500 volts.
Implement controls for electrical hazards, energized work, short-circuit prevention, lifting operations, chemical handling, and battery assembly.
Partner with EHS and Quality to develop JSAs, procedures, PPE requirements, and emergency response protocols.
Promote safe behaviors through hands-on leadership and daily production activities.