Cell Formation 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 filling, formation, and aging conditions 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 electrolyte filling, wetting, formation, degassing, final sealing, aging, grading, and other related processes as applicable.
• Identify systemic bottlenecks and chronic yield losses across formation and aging using production data (MES, SPC, scrap Pareto, cycler data), lead root-cause analysis with 8D, DOE, and other structured problem-solving methods, and implement and verify lasting solutions. This includes reducing formation and aging cycle time without compromising cell quality.
• Define critical process parameters and critical quality attributes (for example fill volume, wetting time, formation protocol, temperature, pressure, gas generation, and residual moisture) and link them to cell performance, safety, and reliability.
• Design and run DOEs at lab, pilot, and production scale to optimize formation protocols, aging conditions, and grading criteria.
• Write process specifications, formation recipes, parameter sheets, and technology transfer packages, and provide process requirements to Industrialization for equipment specifications.
• Support FAT and SAT on process performance, confirming equipment such as filling machines and formation and grading systems can hold the process window and meet capability requirements, and support process validation (IQ/OQ/PQ).
• Develop end-of-line test methods and acceptance criteria, including capacity, OCV, ACIR/DCIR, self-discharge (K-value) screening, and leak testing, and define cell grading and matching rules.
• Partner with Quality to develop PFMEAs, control plans, SPC limits, and reaction plans for formation and aging processes.
• Use formation and grading data to give feedback on upstream electrode and assembly issues, working with the other process development teams to close the loop.
• Provide design-for-manufacturing input to Cell Product Development and evaluate new electrolytes, additives, and cell designs for manufacturability.
• Evaluate new formation 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 Chemical Engineering, Electrochemistry, or 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 filling, formation, aging, or grading process engineering.
• Hands-on process experience with one or more of the following: electrolyte filling, wetting, formation, degassing, sealing, aging, grading, or other related processes.
• Understanding of SEI formation and how filling, formation, and aging conditions drive cell capacity, impedance, self-discharge, and reliability.
• 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 cell test and analysis methods, such as cycler data analysis, OCV/ACIR measurement, self-discharge screening, and electrochemical analysis (dQ/dV, EIS).
• Experience working with large data sets from formation and grading systems; Python or SQL skills are a plus.
• 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.