Formation & Ageing Process Engineer - Battery Cells

Enersys; Greenville (SC); On-site; USD 90,000 - 130,000; Full time

Job summary

EnerSys in Greenville, SC is seeking a Process Engineer Formation & Ageing - Battery Cells to lead development, optimization, and industrialization of formation, ageing, grading, and end-of-line processes for cylindrical Li-ion cells.

This role interfaces with process engineering, cell development, production, quality, maintenance, automation, EHS, and equipment suppliers to scale from pilot to high-volume manufacturing.

Qualifications

• Bachelor's degree in a technical discipline related to battery technology.

Responsibilities

• Develop, optimize, and sustain formation, ageing, grading, and end-of-line manufacturing processes for cylindrical lithium-ion battery cells.
• Define, validate, and maintain formation recipes, including charge/discharge parameters, voltage limits, current limits, rest periods, cycle sequencing, and safety controls.
• Establish and optimize ageing strategies, including stabilization criteria, self-discharge screening, open-circuit voltage monitoring, leakage detection, and grading methodologies.
• Analyze process and test data including voltage curves, current response, capacity results, DCIR measurements, temperature profiles, OCV drift, and process performance indicators.
• Implement process improvements that enhance product quality, manufacturing yield, throughput, cycle times, operational efficiency, and cost performance.
• Collaborate with automation, MES, data engineering, and quality teams to ensure traceability, recipe management, process control, and data integrity.
• Investigate and resolve process deviations, equipment issues, quality concerns, safety events, and abnormal cell performance.
• Partner with cell development, electrode manufacturing, cell assembly, electrolyte filling, quality, and product engineering teams to understand upstream process impacts on cell behavior and performance.
• Apply structured problem-solving methodologies, including Root Cause Analysis, 8D, DoE, SPC, Ishikawa, and Lean Manufacturing principles.

Education

Bachelor's degree in Electrical Engineering, Materials Science, Battery Technology, Chemical Engineering, Automation Engineering, Manufacturing Engineering, or a related technical discipline

Job description

EnerSys in Greenville, SC is seeking a Process Engineer Formation & Ageing - Battery Cells to lead development, optimization, and industrialization of formation, ageing, grading, and end-of-line processes for cylindrical Li-ion cells.

This role interfaces with process engineering, cell development, production, quality, maintenance, automation, EHS, and equipment suppliers to scale from pilot to high-volume manufacturing.