Staff Cell Assembly Engineer

Blue Current•Hayward, CA

1d•$125,100 - $167,000•Onsite

About The Position

Blue Current (the “Company”) is the industry leader in the development of silicon solid state batteries. Free of flammable liquid electrolytes, Blue Current’s fully dry, inherently safe batteries significantly reduce risks to human and environmental health while providing a higher-performance alternative to traditional lithium-ion batteries. Blue Current’s silicon-based platform is highly adaptable, enabling a cost-effective solution for both the mobility and stationary storage markets. Blue Current’s team works out of its state-of-the-art headquarters and pilot line facility in Hayward, California. To learn more about Blue Current, Inc., visit http://bluecurrent.com. The Staff Cell Assembly Engineer is Blue Current’s technical authority for cell assembly, responsible for establishing and validating processes and tooling for large-format solid-state battery cells. This engineer will scale processes from a nascent R&D state to larger formats by working closely with team members in other functions such as equipment engineering, process engineering, and cell engineering. Blue Current’s solid-state technology is novel, and successful candidates will be able to advance the technology in areas with little precedent in literature or traditional lithium ion cells. This will require transforming open-ended concepts into actionable goals and timelines. Ideal candidates are experienced engineers or scientist with backgrounds in electrochemical engineering, process scaleup, project management, and vendor relationship management.

Requirements

PhD (with 3+ years of relevant experience), Master's (with 6+ years of relevant experience), Bachelor's (with 8+ years of relevant experience) in Chemical Engineering, Materials Science, Chemistry, or a related field, or equivalent combination of education and industry experience
Experience troubleshooting and diagnosing assembly-related failures using advanced characterization techniques such as X-ray imaging or electrochemical impedance spectroscopy, going beyond visual inspection to identify root causes
Experience translating process requirements into tooling or fixture specifications, and working iteratively with engineers to validate that the resulting hardware meets process needs
Deep understanding of solid-state or lithium-ion battery electrochemistry sufficient to design characterization strategies, interpret complex data sets, and connect assembly process decisions to cell performance
Ability to design experiments, analyze results, and draw data-driven conclusions in the absence of established reference points, and to synthesize findings into process specifications and documentation
Ability to communicate process strategy, capability gaps, and scale-up readiness clearly to audiences across engineering, quality, and executive teams
Hands-on experience with the full assembly sequence, including electrode handling, lamination, layer stacking, and pouch sealing, with a demonstrated history of driving improvements
Demonstrated commitment to maintaining a safe and secure work environment, including adherence to workplace safety protocols, data privacy standards, and confidentiality requirements.
Proven ability to identify and appropriately escalate potential risks to personnel, customers, or sensitive information.
Demonstrated ability to communicate and collaborate effectively with individuals of diverse backgrounds, perspectives, and working styles.
Track record of maintaining professionalism, integrity, and discretion in all workplace interactions.
Demonstrated ability to independently prioritize, execute, and follow through on responsibilities with minimal supervision.
Proven track record of setting measurable goals, meeting deadlines, and taking initiative to resolve challenges proactively.
Demonstrated commitment to quality and continuous improvement in delivering work product, solutions, and outcomes within area of expertise.
Ability to evaluate options critically and apply sound judgment to identify the most effective and scalable solution.
Demonstrated ability to quickly acquire new skills, tools, or domain knowledge in response to evolving business needs.
Proven track record of applying creative or unconventional thinking to solve problems.
Demonstrated ability to deliver results in resource-constrained environments by maximizing existing tools, processes, and partnerships.
Proven ability to adapt and find effective solutions in ambiguous or rapidly changing situations.
Demonstrated commitment to understanding and exceeding the needs of internal and/or external customers.
Track record of building and maintaining strong, trust-based relationships that drive positive outcomes for all stakeholders.
Able to pass a respirator fit test and wear a respirator periodically.
Regularly works in an active manufacturing and laboratory environment; standing and walking for a significant portion of the workday (approximately 4-6 hours per day)
Frequent interaction with process equipment, requiring manual dexterity and the ability to make detailed visual inspections of materials and coated electrodes
Occasional lifting of items up to 30 lbs (e.g., material containers, equipment components)
Prolonged periods of screen-based work for data analysis, documentation, and communication
Regular use of personal protective equipment (PPE) including safety glasses, gloves, and lab coat; additional PPE may be required depending on materials handled
Applicants must be authorized to work in the U.S. without the need for sponsorship now or in the future.

Nice To Haves

Prior experience with solid-state battery assembly specifically, including firsthand familiarity with the unique handling and process challenges of solid-state electrode materials
Experience with dry room or controlled environment assembly processes, including operational constraints, tool design considerations, material handling requirements, and quality implications of controlled atmosphere work
Demonstrated experience leading the translation from manual to semi-automated or automated assembly operations, including contributing to equipment specification, process transfer planning, and validation of automated systems against manually established process baselines
Experience leading cell assembly scale-up efforts, including formal identification of critical process parameters, documentation of process knowledge for manufacturing transfer, and engagement with manufacturing engineering teams on process readiness criteria
Experience leading or owning PFMEA exercises on novel processes and driving corrective actions to closure

Responsibilities

Owns cell assembly processes for Blue Current’s solid-state battery platform in all facets, from new process development, to scaleup, and through quality system implementation
Collaborates closely with Cell Engineering, R&D, and Facilities to design and implement equipment, develop and scale large-format cell assembly processes, and improve process yield
Serves as a key technical interface with assembly equipment vendors and external development partners. Leads vendor evaluation, equipment specification, and FAT/SAT activities
Characterizes and formally documents the relationship between assembly process parameters and cell structural and electrochemical outcomes
Applies and establishes use of advanced metrology techniques in partnership with the Metrology and Cell Engineering teams, including X-ray imaging, electrochemical characterization, and electrochemical impedance spectroscopy to evaluate assembly quality and diagnose process failures
Owns the assembly-stage quality system in partnership with the Quality team, including defining visual inspection criteria, edge alignment and layer tolerancing standards, acceptance criteria for finished cells, and the process control framework for monitoring ongoing assembly quality
Collaborates with other engineers, and mentor junior engineers as appropriate by providing technical direction on complex process challenges, reviewing experimental design and data interpretation, and developing team capability in assembly process fundamentals
Leads PFMEA and root cause analysis activities for assembly processes. As part of this activity, the engineer is expected to develop systems to monitor and respond to defects or process deviations, and to implement/document the problems and corrective actions.
Represents the cell assembly function in executive and cross-functional technical reviews, communicating process status, capability gaps, and scale-up readiness in a form that informs strategic and resourcing decisions
Contributes to manufacturing execution system (MES) development and implementation from the assembly process perspective, including defining what process data must be captured to support quality traceability and yield improvement
Collaborates with electrode process and cell engineering teams to ensure assembly process decisions account for upstream material and electrode constraints and downstream cell performance requirements
Leads projects by developing clear, actionable plans with defined milestones and success metrics, managing timelines and cross-functional dependencies effectively, and ensuring high-quality, on-schedule execution
Supports a strong safety culture by following and improving laboratory safety practices, demonstrating exemplary experimental techniques, and helping implement best-practice updates
Other duties as assigned, consistent with the scope and level of this position