Sr Manager, Battery Scaleup

Blue Current•Hayward, CA

4d•$165,000 - $200,000•Onsite

About The Position

The Sr Manager, Battery Scaleup leads battery assembly engineering in Advanced Manufacturing, transforming coated electrodes into finished, validated large-format cells, modules, and packs and scaling these products through pilot and commercial production. The role owns battery assembly process development, with emphasis on equipment and process scale-up, and partners with Equipment and Process Scaleup on assembly equipment and with Electrode Scaleup on incoming electrode specifications. The position also leads large-format cell validation and testing, including external validation and safety testing, in partnership with Cell Engineering’s test engineering team. As a member of the core battery module and pack concept team, the leader contributes assembly and productization perspectives, identifying opportunities to improve module and pack assembly and testing through cell-level processes. The role builds and leads engineering teams, drives safety and quality practices, and defines requirements for larger demonstration and gigafactory-scale facilities. The work takes place regularly in active manufacturing, laboratory, and dry room environments. Travel is estimated at 10–15% of working time, domestically and internationally. Standard weekday business hours apply, with occasional off-hours availability potentially required during builds, validation campaigns, or equipment installations. Applicants must be authorized to work in the United States without current or future sponsorship.

Requirements

B.S. in Chemical Engineering, Mechanical Engineering, Materials Science, or a similar field.
At least 8 years of experience in process engineering, manufacturing engineering, process development, or scale-up within batteries, advanced materials, chemicals, semiconductors, or a related manufacturing industry.
Experience developing and scaling battery assembly processes at one or more of the cell, module, or pack levels.
At least 3 years of experience leading engineers or technical teams in a process development or manufacturing environment.
Experience specifying battery assembly equipment or tooling and taking it through acceptance testing and qualification.
Experience with battery testing and diagnosing assembly-related failures.
Understanding of how assembly process parameters affect final battery performance and which parameters are critical to quality.
Proficiency with process development and problem-solving methods, including design of experiments, statistical process control, root cause analysis, and FMEA.
Ability to coordinate validation work across internal test teams and external test laboratories.
Ability to communicate process status, validation results, and risks clearly to senior leadership.
Demonstrated commitment to maintaining a safe and secure work environment, following workplace safety protocols, data privacy standards, and confidentiality requirements; ability to identify and appropriately escalate potential risks.
Ability to communicate and collaborate effectively with people of diverse backgrounds, perspectives, and working styles, while maintaining professionalism, integrity, and discretion.
Ability to independently prioritize, execute, and follow through with minimal supervision; track record of setting measurable goals, meeting deadlines, and proactively resolving challenges.
Commitment to quality and continuous improvement, sound judgment in evaluating options, and ability to identify effective, scalable solutions.
Ability to learn new skills, tools, or domain knowledge quickly and apply creative thinking to solve problems.
Ability to deliver results in resource-constrained or changing environments by using available tools, processes, and partnerships effectively.
Commitment to understanding and exceeding internal and external customer needs and building trust-based working relationships.
Able to work regularly in active manufacturing, laboratory, and dry room environments, including standing and walking for a significant portion of the workday.
Able to work around assembly equipment, energized cells, modules, packs, and electrical test equipment while following applicable battery and electrical safety protocols.
Able to occasionally lift items up to 25 lbs.
Able to perform prolonged screen-based work for data review, planning, documentation, and communication.
Able to use personal protective equipment, including safety glasses, gloves, and a lab coat, with additional equipment as required by materials handled.
Able to pass a respirator fit test and wear a respirator periodically.
Able to travel an estimated 10–15% of working time, domestically and internationally.
Able to provide occasional off-hours availability during builds, validation campaigns, or equipment installations.
Authorized to work in the U.S. without the need for sponsorship now or in the future.

Nice To Haves

M.S. or Ph.D. in Mechanical Engineering, Chemical Engineering, Electrical Engineering, or another relevant field.
Large-format battery cell assembly experience.
Experience with external cell validation and safety testing, such as UN 38.3 or UL standards.
Experience with battery module or pack design, assembly, or testing.
Solid-state cell assembly experience.
Experience transitioning manual assembly to semi-automated or automated operations.
Experience in dry room or other humidity-controlled manufacturing environments.

Responsibilities

Build and lead the battery assembly engineering team in Advanced Manufacturing; set priorities, coach employees, manage performance, develop technical depth, and maintain rigorous safety and quality practices.
Own cell assembly process development across electrode handling, punching, alignment, lamination, stacking, tab welding, and sealing, with a focus on quality, throughput, and holistic process improvement.
Partner with Equipment and Process Scaleup on assembly equipment design, selection, procurement, acceptance testing, and implementation, and define the process requirements the equipment must meet.
Set cell assembly process specifications and work with Process Quality on control points and acceptance criteria for finished cells, modules, and packs.
Develop a roadmap with the module and pack development team, provide design input, and build a team to develop and implement necessary module and pack processes and quality practices.
Work with Electrode Scaleup on incoming electrode specifications and handoff requirements, and resolve issues at the interface between finished electrodes and cell assembly.
Lead large-format cell validation and testing with Cell Engineering’s test engineering team, including coordination of external validation and safety testing.
Lead root-cause investigations into assembly defects and cell failures attributable to assembly, and drive corrective actions to closure.
Translate Research and Development and Cell Engineering requirements into assembly processes and feed assembly learnings back to shorten iteration cycles.
Contribute assembly and productization insight to battery module and pack concepts, identifying synergies between cell assembly and testing and module and pack assembly and testing.
Define cell, module, and pack assembly requirements for larger demonstration and gigafactory-scale facilities with Equipment and Process Scaleup, Facilities, Environmental Health and Safety, and executive leadership.
Perform other duties as assigned, consistent with the scope and level of the position.