Job PurposeWe are looking for a hands-on and highly motivated Process Engineer - Electrode Coating to support the development, optimization, and scale-up of lithium-ion battery electrode manufacturing processes. In this role, you will focus on roll-to-roll electrode coating and drying processes for cathode and/or anode electrodes, working closely with cell engineering, R&D, quality, production, maintenance, and equipment suppliers. This position requires specialized expertise in lithium-ion battery electrode manufacturing and will play a critical role in the industrialization, technology transfer, and startup of EnerSys' advanced battery Gigafactory operations.
Essential Duties and Responsibilities- Develop, optimize, and stabilize electrode coating and drying processes for lithium-ion battery electrodes.
- Define and improve key process parameters such as coating gaps, pump rate, web speed, web tension, drying temperature profile, air flow, and solvent removal conditions.
- Support process transfer from laboratory scale to pilot line and production scale, ensuring robust manufacturability and reproducible electrode quality.
- Analyze and troubleshoot coating defects such as streaks, agglomerates, pinholes, edge defects, cracking, delamination, thickness variation, and poor adhesion.
- Plan, execute, and evaluate structured trials and design-of-experiments activities to improve process capability, yield, throughput, and product performance.
- Collaborate with slurry mixing, calendering, slitting, cell assembly, quality, and product engineering teams to ensure coating output meets downstream requirements.
- Define process windows, control plans, inspection criteria, and acceptance limits for coated electrodes.
- Support equipment commissioning, process validation, FAT/SAT activities, ramp-up, and continuous improvement projects.
- Create and maintain work instructions, SOPs, process specifications, trial reports, and technical documentation.
- Promote safe, clean, and disciplined operation of electrode coating equipment in line with EHS and quality standards.
Qualifications- Bachelor's or Master's degree in Chemical Process Engineering, Materials Science, Mechanical Engineering, Process Engineering, or a related technical discipline.
- Relevant experience in electrode coating, roll-to-roll coating, thin-film coating, battery manufacturing, or a comparable high-precision production process.
- Good understanding of lithium-ion battery electrode manufacturing, including slurry behavior, coating, drying, calendaring, and electrode quality requirements.
- Experience with coating technologies such as slot-die, comma bar, doctor blade, or similar continuous coating processes.
- Ability to interpret process data, identify root causes, and implement effective corrective and preventive actions.
