Sr. Process Cell Engineer - Formation - Battery Cell Development Center

• Optimize charge/discharge sequences current profiles rest periods and temperature profiles for initial cell activation and capacity calibration.
• Define/Refine formation protocol parameters for scale (C-rates voltage limits temperature setpoints voltage plateau criteria self-discharge limits) to condition cells and establish accept/reject criteria.
• Continuously improve formation throughput and yield - tuning charging rates minimizing cycle time and eliminating inconsistencies while avoiding cell damage.
• Design execute and analyze Design of Experiments (DoEs) to optimize formation degassing and capacity grading cycles.

• Transition lab-scale formation procedures to rate-capable processes.
• Define scalable process parameters (batch sizing temperature control per batch automation of process steps) that are directly transferable to gigafactory environments.
• Develop recipes specifications and run rules that support repeatable cost-effective formation at scale.
• Partner with central process engineering and product engineering teams to validate that new cell designs chemistries and dimensions can be effectively formed.

• Support Site Acceptance Testing (SAT) commissioning and qualification of formation equipment.
• Coordinate with maintenance and operations teams to troubleshoot equipment issues promptly minimizing downtime during formation operations
• Partner with maintenance to develop preventive maintenance protocols calibration schedules and equipment specifications to ensure consistent performance and uptime.

• Partner with quality to establish post-formation quality tests (capacity voltage profile analysis self-discharge safety screening) to verify cells meet specifications.
  • Analyze trend formation data (charge capacity voltage vs. time temperature) using software tools to detect anomalies improve yield and inform process decisions.
  • Establish Process Failure Mode and Effects Analysis (PFMEA) and Statistical Process Control (SPC) methods to ensure consistent high-quality production.
  • Maintain detailed manufacturing procedures and operating instructions

• Adhere to and champion all GM safety standards battery safety guidelines and regulatory requirements when handling cells and performing formation operations.
• Ensure proper use of PPE safe handling of flammable electrolytes and adherence to protocols preventing other cell-level hazards.
• Support EHS procedures audits and incident investigations related to formation processes.

• Collaborate with electrochemists battery engineers manufacturing engineers quality engineers and operations to align formation requirements with product development and build schedules.
• Conduct root-cause analysis when cells fail to meet specifications and implement corrective actions.
• Drive continuous improvement by evaluating new formation technologies and methods (e.g. pulse charging advanced SEI formation techniques) that can improve cell quality or reduce cycle time.
• Scale up lessons learned from the Wallace Battery Cell Innovation Center (WBCIC) into BCDC manufacturing systems.

• BS or higher in Chemical Mechanical Electrical or Materials Engineering.
• 5+ years of experience in battery cell manufacturing or development with direct involvement in formation testing or electrochemical process engineering.
• Deep understanding of lithium-ion cell electrochemistry including SEI layer formation voltage/current behaviors and cell conditioning.
• Experience translating lab-scale processes into scalable processes.
• Proficiency with data analysis tools (Python Minitab Excel) for process characterization and optimization.
• Experience with DOE PFMEA and SPC methodologies.
• Strong analytical problem-solving and troubleshooting skills.
• Hands-on experience with formation equipment PLC-based controls and automated test systems.
• Ability to work off-shifts weekends or holidays as needed to support build campaigns.
• Travel Requirements: Ability to travel 10% to support new equipment and supplier activities.

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