Process Engineer, Pack

Stealth-mode Battery Startup; United States; On-site; USD 90,000 - 130,000; Full time

Job summary

Stealth-mode Battery Startup in the United States is seeking a Pack Process Engineer to turn evolving battery pack designs into safe, repeatable, and scalable assembly processes. This hands-on role involves assembling or tearing down packs, troubleshooting, designing quick fixtures, running experiments, analyzing data, and writing SOPs.

You will own key pack assembly processes from prototype through production ramp, collaborating with design, test, quality, and operations to improve quality,

Qualifications

• Bachelor’s or Master’s degree in mechanical, manufacturing, or industrial engineering discipline—or equivalent practical experience.
• Experience in manufacturing engineering, process engineering, new product introduction, or hardware-focused roles.
• Experience developing pack assembly processes through production scale-up and/or technology transfer.
• Strong mechanical aptitude and willingness to work directly with tools, parts, fixtures, and equipment.
• Ability to create quick, fit-for-purpose fixture and tooling designs using CAD.
• Experience planning structured experiments, analyzing results, and translating findings into process decisions.
• Ability to write clear, concise SOPs and work instructions for manufacturing teams.
• Understanding of engineering drawings, tolerances, fasteners, adhesives, joining methods, and basic metrology.
• Approach to ambiguous manufacturing problems via observation, hands-on testing, and data analysis.
• Effective communication with engineers, technicians, operators, and cross-functional partners.

Responsibilities

• Develop, document, and improve battery pack assembly processes from prototype.
• Perform hands-on mechanical assembly, rework, troubleshooting, and teardown of packs.
• Provide direct engineering support during builds, process trials, and production ramp.
• Translate product requirements and engineering drawings into practical, repeatable processes.
• Characterize critical process parameters and process windows, optimizing for OEE.
• Support PFMEAs, control plans, capability studies, gauge R&R studies, and other analyses.
• Influence pack design to improve manufacturability based on process feedback.
• Create operator-friendly SOPs, work instructions, process specifications, and diagnostics.

Skills

Mechanical aptitude

SOP writing

Data analysis

Process development

New product introduction

Engineering drawings

Communication

Education

Bachelor’s or Master’s in mechanical/manufacturing/industrial engineering or equivalent

Tools

CAD

Job description

About the Company

We are a stealth-mode battery startup developing cutting-edge battery technology. Our mission is to revolutionize battery technology to accelerate the global transition to clean energy. By leveraging innovative materials, advanced manufacturing techniques, and next-generation energy storage architectures, we are building the future of sustainable energy.

Can’t find the company name?
It’s not you, it’s us! We’re really excited about the potential of our technology, product, and mission, and have chosen to remain in stealth mode. If your skillset is aligned with what we’re looking for, the team will reach out to schedule your interview and tell you a bit more about us (ie. who we are).

About the Role

As a Pack Process Engineer at Stacked Energy, you’ll work at the intersection of product development, manufacturing, and operations to turn evolving battery pack designs into safe, repeatable, and scalable assembly processes. This is a highly hands‑on role: on any given day, you might assemble or tear down a pack, troubleshoot a build issue, design a quick fixture, run an experiment, analyze process data, or write an SOP.

You’ll own key pack assembly processes from early prototype builds through production ramp. Your work will improve product quality, operator safety, manufacturing yield, cycle time, and overall production readiness. You’ll collaborate closely with design, test, quality, and operations teams, serving as a critical link between engineering intent and what happens on the manufacturing floor.

What You’ll Do

Process Development

• Develop, document, and improve battery pack assembly processes from prototype

• Perform hands‑on mechanical assembly, rework, troubleshooting, and teardown of

• Provide direct engineering support during builds, process trials, and production ramp.

• Translate product requirements and engineering drawings into practical, repeatable

• Characterize critical process parameters and process windows, optimizing for OEE, by

• Support PFMEAs, control plans, capability studies, gauge R&R studies, and other

• Influence pack design to improve manufacturability based on process feedback.

• Create operator-friendly SOPs, work instructions, process specifications, and

Process Scale-Up

• Translate pack process requirements into equipment specifications, requests for quotation (RFQs), and acceptance criteria.

• Collaborate with the Equipment Team to identify and evaluate equipment vendors, integrators, and technical partners.

• Lead technical proposal reviews, design reviews, equipment demonstrations, and vendor selection.

• Serve as the technical owner for vendors from concept through production acceptance.

• Manage vendor performance against technical requirements, milestones, budget, schedule, and quality expectations.

• Coordinate factory acceptance testing, site acceptance testing, installation, commissioning, and qualification.

Fixtures, Tooling & Equipment

• Design and build practical fixtures, jigs, gauges, and other tooling for pack assembly and

• Develop tooling concepts that improve operator safety, assembly quality, ergonomics,

• Support equipment selection, installation, qualification, and process validation.

• Troubleshoot tooling and equipment issues directly on the production floor.

Who you are

• Bachelor’s or Master’s degree in mechanical, manufacturing, or industrial engineering discipline—or equivalent practical experience.

• You have + years of experience in manufacturing engineering, process engineering, new product introduction, or a similar hardware‑focused role.

• You have experience developing pack assembly processes through production scale‑up and/or technology transfer.

• You have strong mechanical aptitude and are willing to spend significant time working directly with tools, parts, fixtures, and equipment.

• You can create quick, fit‑for‑purpose fixture and tooling designs using CAD.

• You have experience planning structured experiments, analyzing results, and translating findings into process decisions.

• You can write clear, concise, and usable SOPs and work instructions for manufacturing teams.

• You understand engineering drawings, tolerances, fasteners, adhesives, joining methods, and basic metrology.

• You approach ambiguous manufacturing problems through careful observation, hands‑on testing, and data analysis.

• You communicate effectively with engineers, technicians, operators, and cross‑functional partners.

Why Join Us?

• Innovative Technology: Work on cutting‑edge energy storage solutions that power the future.

• Career Growth: Opportunities to work on high‑impact projects and advance in a growing industry.

• Competitive Benefits: Comprehensive health, wellness, and professional development programs.

• Mission‑Driven Culture: Be part of a team that is shaping the future of sustainable energy through innovation and excellence.

We are an equal opportunity employer and we do not discriminate on the basis of race, gender, sexual orientation, gender identity/expression, national origin, disability, age, genetic information, veteran status, marital status, pregnancy or related condition, or any other basis protected by law.