Sr Manager, Battery Scaleup

Position Summary

The Sr Manager, Battery Scaleup leads all battery assembly engineering in Advanced Manufacturing, turning coated electrodes into finished, validated large-format cells, modules, and packs, and scaling each of those products through pilot and commercial production. This leader owns battery assembly process development with a strong emphasis on equipment and process scale-up, working with the Equipment and Process Scaleup team to design, procure, and implement assembly equipment, and with the Electrode Scaleup team on incoming electrode specifications. The role extends past the assembly line into large-format cell validation and testing, including external validation and safety testing, in partnership with Cell Engineering's test engineering team. This leader is also part of the core group shaping Blue Current's battery module and pack concepts, bringing an assembly and productization perspective and finding where cell-level processes can make module and pack assembly and testing faster and better. Success means batteries that are built consistently, validated credibly, and ready to scale.

Essential Functions & Responsibilities

• Builds and leads the battery assembly engineering team in Advanced Manufacturing, setting priorities, coaching, managing performance, developing technical depth, and driving/maintaining rigorous safety and quality practices
• Owns cell assembly process development across electrode handling, punching, alignment, lamination, stacking, tab welding, and sealing, with a focus on quality, throughput, and holistic process improvement
• Partners with the Equipment and Process Scaleup team on assembly equipment design, selection, procurement, acceptance testing, and implementation, defining the process requirements equipment must meet
• Sets cell assembly process specifications and works with Process Quality on control points and acceptance criteria for finished cells, modules, and packs
• Develops roadmap with, and gives design input to, module and pack development team, and builds a team to build modules and packs, including all necessary process and quality development/implementation
• Works with the Electrode Scaleup team on incoming electrode specifications and handoff requirements, and resolves issues at the process interface between finished electrodes and cell assembly
• Leads large-format cell validation and testing in partnership with Cell Engineering's test engineering team, including coordination of external validation and safety testing
• Leads root cause investigations into assembly defects and cell failures attributable to assembly, and drives corrective actions to closure
• Translates Research and Development and Cell Engineering requirements into assembly processes, and feeds assembly learnings back to shorten iteration cycles
• Contributes assembly and productization insight to battery module and pack concepts as part of the core concept team, identifying synergies between cell assembly and testing and module and pack assembly and testing
• Defines cell, module, and pack assembly requirements for larger demonstration and gigafactory-scale facilities with Equipment and Process Scaleup, Facilities, Environmental Health and Safety, and executive leadership
• Other duties as assigned, consistent with the scope and level of this position.

Minimum Qualifications

Education

• B.S.in Chemical Engineering, Mechanical Engineering, Materials Science, or similar field

Experience

• 8+ years of experience in process engineering, manufacturing engineering, process development, or scale-up within batteries, advanced materials, chemicals, semiconductors, or a related manufacturing industry.
• Experience developing and scaling battery assembly processes (in one or more of cell, module, or pack-level batteries)
• 3+ years of experience leading engineers or technical teams in a process development or manufacturing environment
• Experience specifying battery assembly equipment or tooling and taking it through acceptance testing and qualification
• Experience with battery testing and diagnosing assembly-related failures

Skills & Knowledge

• Understanding of how assembly process parameters affect final battery performance, and which ones are critical-to-quality
• Proficiency with process development and problem-solving methods, including design of experiments, statistical process control, root cause analysis, and FMEA
• Ability to coordinate validation work across internal test teams and external test laboratories
• Ability to communicate process status, validation results, and risk clearly to senior leadership

Certifications / Licenses

• N/A

Preferred Qualifications

• M.S. or PhD in Mechanical Engineering, Chemical Engineering, Electrical Engineering, or other relevant fields
• Large-format battery cell assembly experience, specifically is preferred
• Experience with external cell validation and safety testing (e.g., UN 38.3, UL standards)
• Experience with battery module or pack design, assembly, or testing
• Solid-state cell assembly experience
• Experience transitioning manual assembly to semi-automated or automated operations
• Experience in dry room or other humidity-controlled manufacturing environments

Core Values - Minimum Qualifications

Safety & Security First

For employees, customers, and intellectual property

• 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.

Trust & Respect

Treat everyone with honesty, dignity, and sensitivity. Embrace different perspectives. Be humble.

• 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.

Ownership & Accountability

Take responsibility and action. Set goals and deliver. Don't wait for others.

• 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.

Technical Excellence

Always strive for the best solution possible.

• 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.

Learn & Be Curious

Think outside the box. Always learning.

• 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.

Be Resourceful

Be hungry, frugal, and flexible. Use what you have. Find a way.

• 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.

Delight Customers

Build stronger relationships with internal and external customers.

• 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.

Physical Requirements & Working Conditions

• Regularly works in active manufacturing, laboratory, and dry room environments; standing and walking for a significant portion of the workday
• Work around assembly equipment, energized cells, modules, packs, and electrical test equipment; adherence to all applicable battery and electrical safety protocols is required
• Occasional lifting of items up to 25 lbs
• Prolonged periods of screen-based work for data review, planning, documentation, and communication
• Regular use of personal protective equipment including safety glasses, gloves, and lab coat; additional protective equipment may be required depending on materials handled
• Able to pass a respirator fit test and wear a respirator periodically
• Travel estimated at 10-15% of working time, domestic and international, for factory acceptance testing, external test laboratories, and vendor visits
• Standard weekday business hours; occasional off-hours availability may be required during builds, validation campaigns, or equipment installations

Salary Range

$165,000-$200,000 USD