Staff Electrode Process Engineer

Blue Current•Hayward, CA

2h•$125,100 - $167,000•Onsite

About The Position

The Staff Electrode Process Engineer plays a key role in developing, optimizing, and scaling electrode manufacturing processes at Blue Current, helping advance electrode fabrication from pilot production toward higher-volume manufacturing. Working closely with cell engineering, quality, and manufacturing teams, this position leads process development initiatives, evaluates equipment and process improvements, and resolves complex technical challenges that impact product quality, process capability, and manufacturability. The Staff Electrode Process Engineer provides technical leadership in electrode processing, contributes to scale-up efforts, and helps establish robust, scalable manufacturing methods that support the company's growth and future production needs.

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
Hands-on experience developing and optimizing slurry-based electrode manufacturing processes across mixing, coating, drying, and calendering operations
Track record of selecting, validating, and qualifying process equipment with working knowledge of multiple mixer and coater types across varying process requirements
Experience defining process specifications and QA/QC protocols, including critical parameter identification, measurement method selection, and acceptance criteria
Experience leading cross-functional technical work and communicating findings and recommendations to senior stakeholders
Deep working knowledge of slurry rheology and how mixing and coating process parameters influence electrode microstructure and final properties
Proficiency with statistical methods for process characterization and control, including design of experiments and statistical process control
Proficiency with standard data analysis tools sufficient to process, visualize, and communicate process and quality data
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.
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 owning a process scale-up program from pilot through high-volume production, including making independent technology selection decisions with significant capital or strategic implications
Experience architecting or leading the implementation of a QA/QC or MES system across a manufacturing organization, rather than operating within an existing one
Deep familiarity with solid-state or dry electrode manufacturing processes, including independent evaluation of emerging coating or mixing technologies for potential adoption
Experience serving as the primary technical interface with capital equipment vendors during facility build-out or major equipment procurement cycles
Background applying Six Sigma or similar methodologies at a program leadership level, including training or certifying others
Prior experience with solid-state or dry electrode manufacturing processes, including solvent-free or low-solvent coating approaches
Familiarity with lithium-ion or solid-state battery cell architecture and how electrode properties such as porosity, loading, and thickness influence cell performance
Experience contributing to process scale-up efforts, including equipment specification, process transfer documentation, or qualification runs at increased volume
Background in failure analysis or structured problem-solving methodologies such as PFMEA or Six Sigma
Familiarity with statistical methods for process characterization and control, such as design of experiments or statistical process control
Familiarity with pilot-to-production process validation frameworks, including process capability studies or equipment qualification protocols
Experience working with manufacturing execution systems (MES) or similar production tracking and data management platforms, including participation in their development or implementation

Responsibilities

Leads the development and execution of electrode process improvement and scale-up plans, providing technical input on process design, equipment selection, and manufacturing approaches across mixing, coating, drying, and calendering operations
Establishes process specifications, critical parameter ranges, and qualification criteria that serve as the technical standard against which current and future electrode manufacturing operations are evaluated
Leads the development and implementation of QA/QC systems in partnership with the Quality team, setting the measurement philosophy and acceptance standards that govern finished electrode quality
Drives process scale-up efforts, identifying the technical and equipment gaps between current pilot-scale capabilities and gigafactory-level production requirements, and defining the work needed to close them
Engages directly with equipment vendors and external process contractors, defining technical requirements, evaluating proposals, and holding external parties accountable to deliverables that serve Blue Current's manufacturing strategy
Synthesizes process development findings into clear technical recommendations for senior management and executives, framing complex tradeoffs in terms of cost, risk, timeline, and scalability
Works across cell engineering, quality, and advanced manufacturing teams to ensure electrode process decisions are made with full visibility into upstream material constraints and downstream cell assembly requirements
Mentors junior and mid-level process engineers in experimental design, equipment operation, process characterization, and structured problem-solving
Leads projects by developing clear, actionable plans with defined milestones and success metrics, managing timelines 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