Cell Formation Process Development Engineer

Crosslinked; Belleville (MI); On-site; USD 100,000 - 132,000; Full time

Job summary

Our Next Energy is seeking a hands-on Cell Formation Process Development Engineer in Belleville, MI. You will develop and optimize electrolyte filling, formation, aging, and grading steps for lithium-ion cells from pilot to production, collaborating with product development, industrialization, and manufacturing teams.

The role requires a BS/MS in a relevant engineering field and 2–8 years of experience in cell development or manufacturing.

Qualifications

• Bachelor’s or Master’s degree in Chemical Engineering, Electrochemistry, or Mechanical Engineering; 2–8 years in lithium-ion cell development or manufacturing.
• Hands-on experience with electrolyte filling, wetting, formation, or aging processes; understanding of SEI formation.

Responsibilities

• Own and optimize electrolyte filling, wetting, formation, degassing, aging, and grading processes.
• Define critical process parameters and quality attributes; develop DOEs to optimize formation and aging.
• Write process specs, formation recipes, and transfer packages for Industrialization.
• Support FAT/SAT and equipment validation; ensure process capability and control plans.
• Collaborate with Quality to establish PFMEAs and SPC limits; close the loop with upstream teams.

Skills

electrolyte filling

formation & aging

DOE

PFMEA & control plans

statistical analysis (SPC/8D)

Python/SQL data analysis

Education

Bachelor’s or Master’s in Chemical Engineering / Electrochemistry / Mechanical Engineering

Tools

JMP/Minitab/Python

Job description

Crosslinked

Jobs/Electronic materials/Cell Formation Process Development Engineer

One of 8,202 open polymer and materials roles on Crosslinked, each read for materials, degree, visa and salary. See roles like this

ON

H-1B history This employer has filed H-1B petitions with the U.S. Department of Labor in the past. That is a record of prior filings, not a statement about this role. Whether any given position is eligible for sponsorship is decided by the employer, case by case. Confirm before you apply. From Jan to Dec 2025 it filed 5 H-1B labor applications for scientist and engineer roles.

Cell Formation Process Development Engineer

Our Next Energy

• Belleville, MI,yesterday

BS-level Process Engineering roles on Crosslinked list a median of $116k (762 that show pay). This posting does not list pay.

Develop and optimize electrolyte filling, formation, aging and grading processes for lithium-ion cells from pilot to production.

Worth knowing

Why it is interesting. Hands-on from lab to production floor on cell formation, with defense and aerospace customer programs.

Might not be for you. Process and yield-focused manufacturing work rather than open-ended materials research.

Mostly at the benchDeep specialist BS acceptable

Adjacent materials role:Lithium-ion cell process development: electrolyte filling/wetting, formation, SEI formation, electrolytes and additives, LFP chemistry, electrochemical analysis (dQ/dV, EIS)

H-1B filings

Our Next Energy filed 5 H-1B labor applications for scientist and engineer roles from Jan to Dec 2025.

Most common titles: Principal Engineer, Battery Pack Lead, Staff Engineer, Structures, Process Engineer Cell Assembly. Median filed pay: $116K a year.

From U.S. Department of Labor disclosure data. A filing is a record of past hiring, not a promise about this role, so confirm sponsorship with the employer. Titles and filed pay

• Every employer's filings

Seniority Mid-level

Work On-site

Type Full-time

Degree BS

Experience 2-8 yrs

Industry Energy

Role Process Engineering

Materials lithium-ion cell materials, electrolytes, LFP.

Techniques cycler data analysis OCV/ACIR measurement self-discharge screening dQ/dV EIS.

Role details This role requires a hands-on engineer who is comfortable in the lab, on the pilot line, and on the production floor. The ideal candidate understands how filling, formation, and aging conditions affect cell performance, safety, and reliability, and can work closely with Cell Product Development, Industrialization, Quality, and Manufacturing to make sure what we design can be built consistently, safely, and economically.

Essential Duties

And responsibilities: Own process development for electrolyte filling, wetting, formation, degassing, final sealing, aging, grading, and other related processes as applicable. Identify systemic bottlenecks and chronic yield losses across formation and aging using production data (MES, SPC, scrap Pareto, cycler data), lead root-cause analysis with 8D, DOE, and other structured problem-solving methods, and implement and verify lasting solutions. This includes reducing formation and aging cycle time without compromising cell quality.

Define critical process parameters and critical quality attributes (for example fill volume, wetting time, formation protocol, temperature, pressure, gas generation, and residual moisture) and link them to cell performance, safety, and reliability. Design and run DOEs at lab, pilot, and production scale to optimize formation protocols, aging conditions, and grading criteria. Write process specifications, formation recipes, parameter sheets, and technology transfer packages, and provide process requirements to Industrialization for equipment specifications.

Support FAT and SAT on process performance, confirming equipment such as filling machines and formation and grading systems can hold the process window and meet capability requirements, and support process validation (IQ/OQ/PQ). Develop end-of-line test methods and acceptance criteria, including capacity, OCV, ACIR/DCIR, self-discharge (K-value) screening, and leak testing, and define cell grading and matching rules. Partner with Quality to develop PFMEAs, control plans, SPC limits, and reaction plans for formation and aging processes.

Use formation and grading data to give feedback on upstream electrode and assembly issues, working with the other process development teams to close the loop. Provide design-for-manufacturing input to Cell Product Development and evaluate new electrolytes, additives, and cell designs for manufacturability. Evaluate new formation technologies and process improvements for future lines and line expansions.

Support customer programs, including defense and aerospace programs, through process documentation, audits, technical reviews, and qualification builds. Contribute to building ONE’s intellectual property portfolio.

Qualifications

Bachelor’s or Master’s degree in Chemical Engineering, Electrochemistry, or Mechanical Engineering, or a related field. 2-8 years of experience in lithium-ion cell development or manufacturing, including a minimum of 2 years directly related to filling, formation, aging, or grading process engineering.

Hands-on process experience with one or more of the following: electrolyte filling, wetting, formation, degassing, sealing, aging, grading, or other related processes. Understanding of SEI formation and how filling, formation, and aging conditions drive cell capacity, impedance, self-discharge, and reliability.

Track record of identifying root causes of chronic yield losses or throughput bottlenecks in production and implementing lasting fixes. Strong command of DOE, SPC, statistical analysis (JMP, Minitab, or Python), PFMEA, control plans, and structured problem solving (8D). Experience with cell test and analysis methods, such as cycler data analysis, OCV/ACIR measurement, self-discharge screening, and electrochemical analysis (dQ/dV, EIS). Experience working with large data sets from formation and grading systems; Python or SQL skills are a plus. Experience with LFP chemistry and large-format prismatic cells preferred.

Experience transferring a process from pilot to high-volume production or supporting a production launch is a plus. Experience with IATF 16949, AS9100, or similar quality systems; experience supporting defense or aerospace customers is a plus. Strong written and verbal communication skills, including clear technical documentation.

REASONABLE ACCOMMODATIONS AND EEO: Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions of this position. An individual must be able to perform the essential functions of this position with or without reasonable accommodation. Our Next Energy Inc. (ONE) is an equal opportunity employer and is committed to providing equal employment opportunities to all employees and applicants without regard to disability or any other protected status in accordance with applicable federal, state, and local laws.

Connected

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Common questions

• Does Our Next Energy sponsor H-1B visas?
  Our Next Energy has filed H-1B petitions with the US Department of Labor in past years, but this specific posting does not explicitly mention sponsorship for the Cell Formation Process Development Engineer role. Confirm with the employer before applying if visa support is required.
• Where is the Cell Formation Process Development Engineer role at Our Next Energy based?
  This role is based in Belleville, MI.
• What degree is required for the Cell Formation Process Development Engineer role at Our Next Energy?
  This role asks for a bachelor's degree.
• How many years of experience does this Cell Formation Process Development Engineer role require?
  The posting calls for 2-8 years of relevant experience.
• What polymers or materials does this Cell Formation Process Development Engineer role work with?
  lithium-ion cell materials, electrolytes, LFP.
• What techniques or methods are required for this Cell Formation Process Development Engineer role?
  cycler data analysis, OCV/ACIR measurement, self-discharge screening, dQ/dV, EIS.