Process Engineer Mixing & Coating – Battery Cell Development Center

GM•Warren, MI

2d•Onsite

About The Position

At General Motors, we’re driving the future of mobility through cutting-edge battery cell innovation. As a Process Engineer for electrode Mixing & Coating, you’ll play a critical role in developing and refining cell technologies that power our electric future. This is a hands-on, on-site position at the Battery Cell Development Center where you’ll collaborate with top-tier engineers and researchers to push the boundaries of cell technology. We’re looking for a candidate who is passionate about advancing technologies in battery cells and eager to continuously learn and grow. You will engage directly in a development manufacturing setting, collaborating closely with process, operations, maintenance, quality, and product engineering teams to develop and stabilize scalable manufacturing processes for battery cells.

Requirements

Bachelor’s degree in chemical engineering, Materials Science, Mechanical Engineering, or related engineering field.
3+ years of experience in process engineering, manufacturing engineering, or similar role in: Li-ion battery manufacturing, or Coating, inks, films, or related web-based processes, or Other wet-chemistry / mixing-intensive manufacturing.
Hands-on experience with mixing processes (slurry, inks, coatings, or adhesives) and basic rheology concepts.
Hands-on experience with coating or web handling processes (slot-die, comma bar, gravure, or similar).
Demonstrated ability to design and run DOEs, analyze data, and solve complex process problems with a structured approach.
Strong communication skills and ability to work cross-functionally with operations, maintenance, quality, and suppliers.
Willingness to work in an onsite, pilot manufacturing environment with time spent on the production floor.

Nice To Haves

Direct experience in Li-ion electrode manufacturing (slurry mixing, coating, drying, calendaring).
Experience with roll-to-roll coating equipment and web handling (tension control, edge guiding, defect detection).
Familiarity with battery materials (cathode/anode active materials, binders, solvents, conductive additives) and their impact on processability and performance.
Experience in a development, or ramp-up environment (frequent changeovers, trials, and non-steady-state operation).
Working knowledge of SPC, DOE, and basic statistics applied to manufacturing processes.
Experience using manufacturing data systems (historian, MES, quality databases) for troubleshooting and continuous improvement.
Demonstrated commitment to safety, including solvent handling, powder handling, and clean-room or dry-room operations.

Responsibilities

Develop process parameters, operating windows, and work instructions for slurry mixing (cathode and/or anode), optimizing mixing sequences, order of addition, shear rates, temperature, and vacuum/de-aeration conditions.
Characterize slurry rheology and stability to establish acceptance criteria and checks.
Partner with product engineers and suppliers to qualify new active materials, binders, solvents, and conductive additives.
Develop process parameters for roll-to-roll coating (e.g., slot-die, comma bar) and drying for battery cell electrodes.
Tune key settings (web speed, gap, pump settings, tension, oven zones, air flows) to meet coating thickness, uniformity, and defect targets.
Develop and maintain procedures for set-up, startup, changeovers, and shut-down to ensure safe, stable operation.
Interface with calendaring and downstream steps to ensure coating output supports density, porosity, and cell performance targets.
Plan and execute DOEs and structured experiments to expand process windows and improve yield, scrap, and throughput.
Partner with quality to analyze process and quality data and identify root causes of defects (e.g., streaks, agglomerates, edge defects, pinholes, delamination) and implement robust corrective actions.
Support equipment commissioning, debug, and SAT/FAT for new mixing and coating assets or upgrades.
Capture lessons learned and standardized best practices for reuse across campaigns and future lines.
Develop and maintain standard work, SOPs, control plans, and reaction plans for mixing and coating operations.
Work with quality to define CTQs/CTPs, sampling plans, and acceptance criteria for slurry, coated web, and in-process checkpoints.
Maintain clear documentation of trials, parameter changes, risk assessments, and process changes.
Ensure compliance with GM safety standards, EHS requirements, and lean-room/solvent-handling procedures.
Work closely with operations/technicians to train and coach process intent, set-up, troubleshooting, and best practices.
Partner with maintenance and controls/automation team members to improve uptime, diagnostics, and error-proofing.
Collaborate with cell design, formation, and test teams to link electrode process conditions to cell performance and durability.
Communicate technical learnings and recommendations clearly to both technical and non-technical stakeholders.