Battery Life Model Development and Analysis Engineer, Ford Energy

Ford-Motor-Company; Dearborn (MI); Hybrid; USD 74,000 - 166,000; Full time

Benefits offered by this job

Medical, dental, vision coverage

Parental leave and family benefits

Vehicle discount program

Tuition assistance

Paid time off and holidays

Flexible work options

Job summary

Ford Motor Company is seeking a Battery Cell Simulation Engineer in Dearborn, MI, to develop physics-based cell models (P2D/P4D) and translate them into system-level life inputs for BESS. You will calibrate against cycling and aging data, evaluate degradation, and support warranty and lifecycle cost decisions.

The role bridges cell electrochemistry and pack/system performance, with emphasis on thermal-electrochemical coupling, manufacturing variations, and cross-functional collaboration.

Qualifications

• Experience with physics-based battery modeling.
• Ability to translate cell-level models to system-level inputs.
• Familiarity with degradation mechanisms and life prediction.

Responsibilities

• Develop and apply high-fidelity electrochemical models (P2D/P4D).
• Implement cell-level and system-level degradation and life models.
• Couple electrochemical models with thermal effects.
• Incorporate manufacturing variations into models.
• Translate outputs for BESS simulations and warranty projections.
• Calibrate and validate models with experimental data.

Skills

Electrochemical Modeling

P2D/P4D models

System-level life modeling

Python

MATLAB

COMSOL Multiphysics

Education

Bachelor's degree (Chemical/Mechanical/Materials/Physics)

Tools

COMSOL Multiphysics

Python

MATLAB

Job description

In this position...

The Battery Cell Simulation Engineer is responsible for developing and applying advanced electrochemical models (P2D/P4D) to understand battery cell performance, degradation, and lifetime behavior, with direct linkage to system-level life prediction for Battery Energy Storage Systems (BESS). This role builds physics-based cell models to quantify degradation mechanisms and translate them into system-level life simulation inputs, enabling accurate warranty estimation and augmentation strategies. The position acts as a key bridge between cell-level electrochemistry and BESS system performance, supporting data-driven decisions on durability, reliability, and lifecycle cost optimization.

What you'll do...

• Electrochemical Modeling (Primary Focus)
  • Develop and apply high-fidelity electrochemical models, including P2D/P4D lithium-ion battery models and reduced-order models for system integration.
  • Simulate reaction kinetics and transport phenomena, lithium concentration gradients and overpotential, and internal current density and utilization distribution.
  • Evaluate cell capability limits, including power and energy capability, SOC-dependent performance, and rate limitations under different conditions.
• Cell-Level Life & Degradation Modeling
  • Develop physics-based models to predict cell degradation, including SEI growth and side reactions, lithium plating risk and conditions, and loss of active material and impedance growth.
  • Quantify capacity fade and resistance increase over life, and sensitivity to temperature, SOC window, and cycling conditions.
  • Support cell design trade-offs and degradation mitigation strategies.
• Thermal-Electrochemical Coupling
  • Develop coupled electrochemical-thermal models, including heat generation from electrochemical reactions and temperature-dependent kinetics and degradation.
  • Analyze cell temperature gradients and hot spots, and thermal impact on performance and aging.
  • Provide heat generation and degradation sensitivity inputs for system-level modeling.
• Manufacturing Variation & Cell Behavior
  • Incorporate manufacturing-induced variations into cell models, including electrode thickness and loading variation, porosity and density variation from calendaring, and microstructural heterogeneity.
  • Evaluate impact of process variation on performance distribution, and manufacturing defects on degradation and life.
  • Support translation of modeling insights into process control targets and cell consistency and quality improvements.
• System-Level Life Modeling Interface (BESS Integration)
  • Translate cell-level model outputs into system-level inputs for BESS simulations, including degradation rates under varying duty cycles and temperature and usage sensitivities.
  • Support development of system-level life prediction models and duty cycle-based aging simulations.
  • Collaborate with system and CAE teams to ensure consistent model integration and proper scaling from cell to pack to system.
• Warranty Estimation & Augmentation Strategy Support
  • Provide modeling inputs for warranty projections (capacity retention, degradation limits) and performance degradation over service life.
  • Support evaluation of BESS augmentation strategies (e.g., module replacement, capacity add-back) and trade-offs between degradation, performance, and cost.
  • Enable data-driven decisions on lifecycle management and total cost of ownership (TCO).
• Model Calibration & Validation
  • Calibrate models using experimental data, including cycling and aging tests, and EIS, rate capability, and thermal data.
  • Validate performance and degradation predictions vs. test data.
  • Conduct sensitivity analysis, parameter estimation, and uncertainty quantification.
• Cross-Functional Collaboration
  • Work closely with the Ford Battery Modeling Team and BESS system and controls teams.
  • Support external suppliers with model alignment and parameterization.
  • Translate detailed electrochemical insights into system-level engineering decisions.

You'll have...

• Bachelor's degree in Chemical Engineering, Mechanical Engineering, Materials Science, Physics, or related field.
• 3+ years (MS) or 5+ years (BS) of experience in battery modeling or related fields.
• Strong expertise in electrochemical modeling (P2D or equivalent) and lithium-ion battery fundamentals.

Even Better, you may have...

• Master's or PhD in relevant discipline.
• Experience with P2D/P4D electrochemical models and battery degradation and life modeling.
• Familiarity with system-level battery life modeling (BESS or EV) and warranty or lifecycle analysis.
• Understanding of thermal-electrochemical coupling and battery cell manufacturing effects.
• Technical Skills
  • Simulation tools: COMSOL Multiphysics or equivalent.
  • Programming: Python, MATLAB.
  • Strong knowledge of electrochemical systems and transport phenomena, battery degradation mechanisms, and thermal effects in battery cells.
• Key Competencies
  • Electrochemical Modeling Depth — expertise in P2D/P4D and physical interpretation.
  • Degradation & Life Prediction — strong understanding of aging mechanisms and lifetime modeling.
  • Cell-to-System Translation — ability to convert cell physics into system-level life predictions.
  • Multiphysics Integration — electrochemical-thermal coupling capability.
  • Analytical Problem Solving — identifies drivers of degradation and performance variation.
  • Collaboration — works across cell, system, and CAE teams.
  • Communication — translates complex models into actionable insights.
• Location & Travel
  • Location: Dearborn, MI

As an established global company, we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe, or keep you close to home? Will your career be a deep dive into what you love, or a series of new teams and new skills? Will you be a leader, a changemaker, a technical expert, a culture builder…or all of the above? No matter what you choose, we offer a work life that works for you, including:

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time.

This position is a salary grade 6 and ranges from $74,300-$124,500.,

This position is a salary grade 7 and ranges from $86,600-$144,900.

This position is a salary grade 8 and ranges from $99,100-$166,200.

Final determination of salary grade will be based on candidate's skills and experience, and base salary will be set within the applicable range according to job scope, responsibility and competitive market value.

For more information on salary and benefits, click here: https://fordcareers.co/GSR

Visa sponsorship is not available for this position.

Company: As Ford establishes a wholly owned subsidiary focused on Battery Energy Storage Systems, this role will initially be employed by Ford and is expected to transition to the subsidiary within one year.

Candidates for positions with Ford Motor Company must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire.

We are an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, religion, color, age, sex, national origin, sexual orientation, gender identity, disability status or protected veteran status. In the United States, if you need a reasonable accommodation for the online application process due to a disability, please call 1-888-336-0660.

This position is hybrid with a requirement to be onsite four or more days per week.