Process Engineer - NMC Electrode Coating

Enersys; Greenville (SC); On-site; USD 95,000 - 135,000; Full time

Job summary

EnerSys is seeking a hands-on Process Engineer for electrode coating to support development, optimization, and scale-up of lithium-ion battery electrode manufacturing. You will work on roll-to-roll coating and drying for cathode and/or anode materials, collaborating with cell engineering, R&D, quality, production, and suppliers to enable industrialization of EnerSys Giga_factory operations.

This role requires expertise in lithium-ion electrode manufacturing, process transfer, and robust

Qualifications

• Experience with electrode coating processes for lithium-ion batteries.
• Familiarity with roll-to-roll coating and drying steps.
• Ability to interpret process data and drive corrective actions.

Responsibilities

• Develop, optimize, and stabilize electrode coating and drying processes.
• Define process parameters: gaps, pump rate, web speed, tension, drying profile.
• Support scale-up from lab to pilot to production.
• Analyze coating defects and drive improvements.
• Plan trials and DOE to improve yield and throughput.
• Collaborate with slurry, calendering, and QA teams.
• Establish process windows and acceptance criteria.
• Support equipment validation, FAT/SAT, ramp-up, and improvements.
• Create work instructions, SOPs, and docs.

Skills

Electrode coating

Roll-to-roll

DOE

Process data analysis

Education

Bachelor’s or Master’s in Chemical/Process Engineering

Tools

Slot-die coating

Doctor blade

Calendering

Drying equipment

Job description

Job Title: Process Engineer - NMC Electrode Coating

Location: Greenville, SC, US, 29673

Home-based Position: No

Regular/Temporary: Regular

Job Type: Full-Time

Job Description: EnerSys is a global leader in stored energy solutions for industrial applications. We have over thirty manufacturing and assembly plants worldwide servicing over 10,000 customers in more than 100 countries. Worldwide headquarters are located in Reading, PA, USA with regional headquarters in Europe and Asia. We complement our extensive line of Motive Power and Energy Systems with a full range of integrated services and systems. With sales and service locations throughout the world, and over 100 years of battery experience, EnerSys is the power/full solution for stored DC power products.

Job Purpose

We are looking for a hands-on and highly motivated Process Engineer – Electrode Coating to support the development, optimization, and scale-up of lithium-ion battery electrode manufacturing processes. In this role, you will focus on roll-to-roll electrode coating and drying processes for cathode and/or anode electrodes, working closely with cell engineering, R&D, quality, production, maintenance, and equipment suppliers. This position requires specialized expertise in lithium-ion battery electrode manufacturing and will play a critical role in the industrialization, technology transfer, and startup of EnerSys' advanced battery Gigafactory operations.

Essential Duties and Responsibilities

• Develop, optimize, and stabilize electrode coating and drying processes for lithium-ion battery electrodes.
• Define and improve key process parameters such as coating gaps, pump rate, web speed, web tension, drying temperature profile, air flow, and solvent removal conditions.
• Support process transfer from laboratory scale to pilot line and production scale, ensuring robust manufacturability and reproducible electrode quality.
• Analyze and troubleshoot coating defects such as streaks, agglomerates, pinholes, edge defects, cracking, delamination, thickness variation, and poor adhesion.
• Plan, execute, and evaluate structured trials and design-of-experiments activities to improve process capability, yield, throughput, and product performance.
• Collaborate with slurry mixing, calendering, slitting, cell assembly, quality, and product engineering teams to ensure coating output meets downstream requirements.
• Define process windows, control plans, inspection criteria, and acceptance limits for coated electrodes.
• Support equipment commissioning, process validation, FAT/SAT activities, ramp-up, and continuous improvement projects.
• Create and maintain work instructions, SOPs, process specifications, trial reports, and technical documentation.
• Promote safe, clean, and disciplined operation of electrode coating equipment in line with EHS and quality standards.

Qualifications

• Bachelor’s or Master’s degree in Chemical Process Engineering, Materials Science, Mechanical Engineering, Process Engineering, or a related technical discipline.
• Relevant experience in electrode coating, roll-to-roll coating, thin-film coating, battery manufacturing, or a comparable high-precision production process.
• Good understanding of lithium‑ion battery electrode manufacturing, including slurry behavior, coating, drying, calendaring, and electrode quality requirements.
• Experience with coating technologies such as slot‑die, comma bar, doctor blade, or similar continuous coating processes.
• Ability to interpret process data, identify root causes, and implement effective corrective and preventive actions.

EnerSys provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.

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Nearest Major Market: Greenville
Nearest Secondary Market: South Carolina