Battery Life Model Development and Analysis Engineer, Ford Energy

Ford; Dearborn, Northern (MI, KY); Hybrid; USD 90,000 - 165,000; Full time

Benefits offered by this job

Performance-based bonuses

Vehicle discounts

Job summary

Ford Energy in Dearborn, MI, is seeking a Battery Cell Simulation Engineer to develop physics-based cell models (P2D/P4D) and connect them to system-level life for BESS. You will quantify degradation, support warranty projections, and collaborate across Ford teams to optimize durability and cost.

You will calibrate models with experimental data, account for manufacturing variations, and contribute to fast, data-driven decisions shaping the next-gen energy storage systems for Ford.

Qualifications

• 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.

Responsibilities

• Electrochemical Modeling: develop and apply high-fidelity models including P2D/P4D and reduced-order models for system integration.
• Cell-Level Life & Degradation Modeling: predict degradation, SEI growth, lithium plating risk, and loss of active material.
• Thermal-Electrochemical Coupling: create coupled electrochemical-thermal models and analyze temperature effects on aging.
• Manufacturing Variation & Cell Behavior: incorporate process variations affecting electrode thickness, porosity, and density.
• System-Level Life Modeling Interface: translate cell outputs into system-level inputs for BESS simulations.
• Warranty Estimation & Augmentation: provide inputs for warranty projections and augmentation strategies.
• Model Calibration & Validation: calibrate with experimental data and validate predictions against tests.
• Cross-Functional Collaboration: work with Ford Battery Modeling Team and BESS CAE teams.

Skills

Electrochemical modeling

P2D/P4D lithium-ion models

System-level translation

Degradation & life prediction

Multiphysics coupling

Analytical problem solving

Education

Bachelor’s degree in Chemical Engineering

Bachelor’s degree in Mechanical Engineering

Bachelor’s degree in Materials Science

Bachelor’s degree in Physics

Related field

Tools

COMSOL Multiphysics

Python

MATLAB

Job description

Ford Energy is a newly formed, wholly-owned subsidiary of Ford Motor Company dedicated to accelerating U.S. energy independence. Leveraging Ford’s century of manufacturing excellence and world-class battery energy storage systems (BESS) technology, Ford Energy designs, manufactures, and services grid-scale and commercial DC battery energy storage systems (BESS). Ford Energy is uniquely positioned to capture the growing demand for reliable, US-built energy storage systems. We are not just building batteries; we are building the infrastructure for the next generation of the American grid.

Why Ford Energy? At Ford Energy, you have the backing of an industrial manufacturing powerhouse with the agility of a dedicated energy startup offering industry leading technology. We offer a competitive compensation package including performance-based bonuses, Ford vehicle discounts, and the opportunity to shape the energy strategy of one of the world's most iconic brands. Learn more at https://fordenergy.com.

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.

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.