Metallization Process Engineer for TOPCon Solar

T1 Energy; Austin (TX); On-site; USD 110,000 - 160,000; Full time

Job summary

T1 Energy seeks a Cell Metallization Process Engineer for its G2 solar cell fab in Rockdale, Texas. Own metallization steps—screen printing, firing, laser systems—and drive DOE, QC, and process integration to achieve high-efficiency cells at scale.

You will collaborate with cross-functional teams and optimize pastes, furnace profiles, and contact formations, contributing to technology roadmaps and production ramp-up.

Qualifications

• Bachelor's degree or higher in a relevant field.
• 3+ years of process engineering experience in solar cell manufacturing with direct hands-on metallization experience.
• Demonstrated expertise in screen printing process development and optimization for solar cells.
• Strong knowledge of silver and/or aluminum paste chemistry, contact formation mechanisms, and firing furnace control.
• Experience with TOPCon or other advanced cell architectures (PERC, HJT, IBC) is strongly preferred.
• Familiarity with in-line metrology tools for print quality inspection, contact resistance measurement, and IV characterization.
• Experience with DOE methodology, SPC, and statistical data analysis for process optimization.

Responsibilities

• Own statistical process control for metallization at G2, including process excursions in efficiency, microcrack yield, and paste weight, and isolate the parameters that move Voc, Isc, fill factor, and electroluminescence/photoluminescence.
• Maintain controlled documentation on screen printing process parameters and initiate DOEs across both Process and Equipment Engineering teams to isolate and optimize process tuning.
• Oversee the ramp-up of the screen printing module (product manufacturing via printing, firing, light injection, and laser systems) and the testing and sorting module (efficiency grading by current-voltage profiles and fill factors with additional EL/PL analysis).
• Develop front and rear contact metallization processes for TOPCon solar cells with a focus on optimizing furnace thermal profiles, ohmic contact formations, and paste rheology/properties while minimizing contact resistance, environmental contamination, and process-related print defects (including those stemming from upstream process interfaces).
• Work with an interdisciplinary process team to identify interfacial process parameters specific to metallization modules, anti-reflective deposition modules, and emitter formation diffusion modules.
• Drive process characterization and DOE execution across paste formulation, mesh and emulsion parameters, squeegee dynamics, and firing profiles while managing the risk of silver diffusion and metal-silicon interfaces across distinct layers.
• Qualify new paste materials and screen suppliers, evaluating next-generation metallization solutions.
• Partner with equipment engineering teams to troubleshoot metallization-related yield losses and process excursions, including print quality defects, adhesion failures, and firing window issues.
• Collaborate with T1’s Technology teams to develop metallization-related process initiatives for future-state production and optimize interactions with 5GW Dallas plant.

Skills

Screen printing

Firing

Laser systems

DOE methodology

Statistical data analysis

Process control

Metallization expertise

Education

Bachelor's degree or higher in Materials Science, Chemical Engineering, Mechanical Engineering, Electrical Engineering, Physics, or related field

Tools

Python

JMP

Excel

Job description

T1 Energy seeks a Cell Metallization Process Engineer for its G2 solar cell fab in Rockdale, Texas. Own metallization steps—screen printing, firing, laser systems—and drive DOE, QC, and process integration to achieve high-efficiency cells at scale.

You will collaborate with cross-functional teams and optimize pastes, furnace profiles, and contact formations, contributing to technology roadmaps and production ramp-up.