Cell Assembly Process Development Engineer

This role requires a hands-on engineer who is comfortable in the lab, on the pilot line, and on the production floor. The ideal candidate understands how assembly process variables affect cell performance, safety, and reliability, and can work closely with Cell Product Development, Industrialization, Quality, and Manufacturing to make sure what we design can be built consistently, safely, and economically.

ESSENTIAL DUTIES AND RESPONSIBILITIES:

• Own process development for dry cell assembly: electrode notching, stacking, hot pressing, cell assembly, short (hipot/insulation) testing, leak testing, vacuum baking, and other related processes as applicable.
• Identify systemic bottlenecks and chronic yield losses across assembly processes using production data (MES, SPC, scrap Pareto, OEE), lead root-cause analysis with 8D, DOE, and other structured problem-solving methods, and implement and verify lasting solutions.
• Define critical process parameters and critical quality attributes (for example burrs, particles, electrode alignment and overhang, stack pressure, and residual moisture) and link them to cell performance, safety, and reliability.
• Design and run DOEs at lab, pilot, and production scale to establish robust process windows.
• Write process specifications, parameter sheets, and technology transfer packages, and provide process requirements to Industrialization for equipment specifications.
• Support FAT and SAT on process performance, confirming equipment can hold the process window and meet capability requirements, and support process validation (IQ/OQ/PQ).
• Develop in-process inspection and test methods and acceptance criteria, including hipot/insulation, leak, alignment (vision and X-ray), and post-bake moisture.
• Partner with Quality to develop PFMEAs, control plans, SPC limits, and reaction plans for assembly processes.
• Provide design-for-manufacturing input to Cell Product Development and evaluate new materials, components, and design changes for manufacturability.
• Evaluate new assembly technologies and process improvements for future lines and line expansions.
• Support customer programs, including defense and aerospace programs, through process documentation, audits, technical reviews, and qualification builds.
• Contribute to building ONE’s intellectual property portfolio.

QUALIFICATIONS:

• Bachelor’s or Master’s degree in Mechanical Engineering or a related field.
• 2–8 years of experience in lithium-ion cell development or manufacturing, including a minimum of 2 years directly related to cell assembly process engineering.
• Hands-on process experience with one or more of the following: notching, stacking, hot pressing, cell assembly, hipot/short testing, leak testing, vacuum drying/baking, or other related processes.
• Understanding of how assembly defects such as burrs, particles, misalignment, and moisture drive internal shorts, self-discharge, and reliability failures.
• Track record of identifying root causes of chronic yield losses or throughput bottlenecks in production and implementing lasting fixes.
• Strong command of DOE, SPC, statistical analysis (JMP, Minitab, or Python), PFMEA, control plans, and structured problem solving (8D).
• Experience with in-line and offline metrology, such as vision, X-ray/CT, hipot, leak testing, and Karl Fischer moisture analysis.
• Experience working in dry room environments and with moisture-sensitive processes.
• Experience with LFP chemistry and large-format prismatic cells preferred.
• Experience transferring a process from pilot to high-volume production or supporting a production launch is a plus.
• Experience with IATF 16949, AS9100, or similar quality systems; experience supporting defense or aerospace customers is a plus.
• Strong written and verbal communication skills, including clear technical documentation.

 REASONABLE ACCOMMODATIONS AND EEO: 

Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions of this position.  

An individual must be able to perform the essential functions of this position with or without reasonable accommodation.  

Our Next Energy Inc. (ONE) is an equal opportunity employer and is committed to providing equal employment opportunities to all employees and applicants without regard to disability or any other protected status in accordance with applicable federal, state, and local laws.