Principal Process Development Engineer, Powder Scale-Up

Alsym Energy; Malden (MA); On-site; USD 180,000 - 260,000; Full time

Benefits offered by this job

Prime Location

Commuter Friendly

Health & Wellness

Friday Fuel

Health & Dental

Financial Future

Time to Recharge

Family & Security

Job summary

Alsym Energy is seeking a Principal Process Development Engineer to lead the scale‑up of active materials powders and related particle engineering processes for next‑generation energy storage systems.

You will serve as the senior technical authority, maturing powder production from lab to pilot scale and toward volume manufacturing, collaborating with scientists and engineers to meet strict performance requirements.

Qualifications

• Experience scaling inorganic powder processes from lab to production.
• Experience leading end‑to‑end powder and particle scale‑up efforts.
• Strong background in spray drying, co‑precipitation, or hydrothermal methods.
• Experience with calcination, sintering, milling, and sieving.

Responsibilities

• Lead powder and particle scale‑up efforts end‑to‑end.
• Select equipment, design processes, transfer technology, and start pilot lines.
• Collaborate with R&D and external manufacturers for tech transfer.
• Develop control plans and QC/QA programs for consistent performance.
• Mentor junior engineers and guide long‑term scale‑up roadmap.

Skills

Powder scale‑up

Synthesis techniques

Process design

Technology transfer

Pilot-line experience

Colloid/surface chemistry

Quality systems

RCA / FMEA

Particle characterization

Team leadership

Education

BS/MS/PhD in Chemical Engineering or Materials Science/Engineering

Tools

SEM

EDX

XRD

Particle size analyzers

Job description

Job Title

Principal Process Development Engineer, Powder Scale-Up

Job Summary

Alsym Energy Inc. is seeking a hard-working, self-driven and highly technical Principal Process Development Engineer to lead the scale-up of active materials powders, and associated particle engineering processes, for next-generation energy storage systems. In this role, the candidate will serve as the senior technical authority for maturing powder production processes from lab- through to pilot-scale and toward volume manufacturing, working closely with a team of scientists and engineers to deliver products satisfying strict performance requirements. This is a hands‑on leadership role for someone who has built a career scaling inorganic electroactive-powders in an industrial setting and wants to shape the scale‑up strategy for a rapidly growing energy storage company.

Industry Background

Energy storage is one of the fastest-growing sectors in the global energy economy, with annual stationary storage capacity additions projected to grow 23% per year from 2025 to 2035, driven by surging electricity demand from electrification, data centers, and AI infrastructure. Alsym Energy is the leading developer of non-flammable, high-performance, low-cost sodium-ion batteries for AI data centers, utilities, commercial real estate and anywhere else energy storage is needed.

Key Qualifications

• BS, MS, or PhD in Chemical Engineering, Materials Science and Engineering, Chemistry, or a related field.
• Minimum 15+ years of industry experience working with inorganic powders, with a demonstrated track record of scaling one or more powder synthesis processes from the precursor to the final product spanning research through to full- scale production.
• Proven ability to lead powder and particle scale‑up efforts end-to‑end, including equipment selection, process design, technology transfer, and pilot‑line or manufacturing start‑up.
• Deep, hands‑on expertise with synthesis techniques such as spray drying, co‑precipitation, or hydrothermal, including formulation and process optimization to meet particle size or morphological design and performance specifications.
• Significant hands‑on experience with powder processing methods including, calcination, sintering, carbonization, milling, and sieving.
• Strong fundamental understanding of colloid/surface chemistry, with experience optimizing dispersion and surface functionalization strategies.
• Experience establishing control plans and quality control/quality assurance programs, and leading root‑cause and FMEA-driven troubleshooting across process and manufacturing teams.
• Experience in batteries, catalysts, inorganic pigments, ceramics, or specialty materials is highly desired; experience in GMP or other regulated environments and technology transfer to CMOs or pilot facilities is a plus.
• Serve as the principal technical leader for particle engineering and cathode active materials powder scale‑up, developing and executing the strategy for optimizing and controlling properties such as particle size distribution, surface area, morphology, tap density and surface chemistry.
• Lead the design, optimization, and scale‑up of particle engineering processes such as spray drying, milling, calcination, sintering, and carbonization—from lab‑scale research through pilot‑line and into full-scale manufacturing.
• Serve as technical liaison between R&D, and external manufacturing partners, contributing to design of experiments, process documentation, and technology transfer.
• Partner with process development engineers and scientists to sustain and continuously improve existing and new particle engineering processes, including operations and material traceability across the line.
• Institute and own control plans and quality control/quality assurance programs to ensure consistent particle and electrode performance across batches and scales; collaborate across groups to diagnose and troubleshoot performance issues and conduct FMEA/RCA as required.
• Direct particle characterization efforts using techniques such as SEM, EDX, XRD, and particle size analyzers, and coordinate external testing as needed.
• Plan and coordinate experiments between synthesis and prototyping teams in order to establish key relationships between powder properties and electrode and cell level properties and performance characteristics.
• Evaluate the technical capabilities, equipment, and quality systems of prospective contract manufacturers and toll processors to assess fit for scale‑up.
• Mentor and provide technical guidance to junior and mid‑level engineers and scientists, and contribute to long‑term strategic planning for the powder engineering and scale‑up roadmap.

Why Join Us?

At Alsym, we believe in equitable compensation and a healthy work‑life balance. Beyond a competitive salary, we offer a benefits package designed to support you both inside and outside the office.

• Prime Location: We are within easy walking distance of the train station.
• Commuter Friendly: Enjoy the convenience of free on‑site parking.
• Health & Wellness: Stay active with access to our free on‑site gym.
• Friday Fuel: We provide free lunch delivery every Friday to celebrate the end of the work week together.
• Health & Dental: Premium insurance coverage through Blue Cross Blue Shield.
• Financial Future: Every employee is eligible for 401k plans and stock options.
• Time to Recharge: A flexible Paid Time Off (PTO) program to help you find your balance.
• Family & Security: Full eligibility for PFML (Paid Family and Medical Leave).

Our Commitment to You

We maintain a firm Anti-Harassment Policy that includes robust Diversity, Inclusion, Equity, and Gender Protections. We are an equal opportunity employer and value diversity at our company. We do not discriminate on the basis of race, religion, color, national origin, gender, sexual orientation, age, marital status, veteran status, or disability status.

Note: A full, detailed listing of all benefits will be provided following a formal offer of employment.