Process Engineer, Pack

Stealth-mode Battery Startup

About The Position

As a Pack Process Engineer at Stacked Energy, you will work across product development, manufacturing, and operations to turn evolving battery pack designs into safe, repeatable, and scalable assembly processes. This is a hands-on role that includes assembling and tearing down packs, troubleshooting build issues, designing fixtures, running experiments, analyzing process data, and writing standard operating procedures. You will own key pack assembly processes from early prototype builds through production ramp, improving product quality, operator safety, manufacturing yield, cycle time, and production readiness. You will collaborate with design, test, quality, and operations teams, linking engineering intent to manufacturing-floor execution. The role also involves scaling processes through equipment specification and vendor management, as well as designing, building, and troubleshooting fixtures, tooling, and equipment.

Requirements

Bachelor’s or Master’s degree in mechanical, manufacturing, or industrial engineering, or equivalent practical experience.
Experience in manufacturing engineering, process engineering, new product introduction, or a similar hardware-focused role; the number of years is not specified in the posting.
Experience developing pack assembly processes through production scale-up and/or technology transfer.
Strong mechanical aptitude and willingness to spend significant time working directly with tools, parts, fixtures, and equipment.
Ability to create quick, fit-for-purpose fixture and tooling designs using CAD.
Experience planning structured experiments, analyzing results, and translating findings into process decisions.
Ability to write clear, concise, usable SOPs and work instructions for manufacturing teams.
Understanding of engineering drawings, tolerances, fasteners, adhesives, joining methods, and basic metrology.
Ability to address ambiguous manufacturing problems through observation, hands-on testing, and data analysis.
Effective communication with engineers, technicians, operators, and cross-functional partners.

Responsibilities

Develop, document, and improve battery pack assembly processes from prototype builds through production.
Perform hands-on mechanical assembly, rework, troubleshooting, and teardown of battery packs and related components.
Provide engineering support during builds, process trials, and production ramp.
Translate product requirements and engineering drawings into practical, repeatable manufacturing processes.
Characterize critical process parameters and process windows, optimizing for OEE using Design of Experiments and/or production data.
Support PFMEAs, control plans, capability studies, gauge R&R studies, and other manufacturing-quality activities.
Provide process feedback to influence pack design for improved manufacturability.
Create operator-friendly SOPs, work instructions, process specifications, and troubleshooting guides.
Translate pack process requirements into equipment specifications, RFQs, and acceptance criteria.
Collaborate with the Equipment Team to identify and evaluate equipment vendors, integrators, and technical partners.
Lead technical proposal reviews, design reviews, equipment demonstrations, and vendor selection.
Serve as the technical owner for vendors from concept through production acceptance.
Manage vendor performance against technical requirements, milestones, budget, schedule, and quality expectations.
Coordinate factory and site acceptance testing, installation, commissioning, and qualification.
Design and build fixtures, jigs, gauges, and other tooling for pack assembly and testing.
Develop tooling concepts to improve operator safety, assembly quality, ergonomics, and cycle time.
Support equipment selection, installation, qualification, and process validation.
Troubleshoot tooling and equipment issues on the production floor.