Senior Cell Assembly Engineer

Blue Current; Hayward (CA); On-site; USD 111,600 - 160,000; Full time

Job summary

Blue Current in Hayward, CA seeks a Senior Cell Assembly Engineer to own the assembly process for solid-state batteries from electrode handling through finished cells. You will define tooling requirements, supervise QA/QC, and collaborate with multiple engineering teams to ensure high-quality, scalable production.

The role requires advanced characterization skills (X-ray, electrochemical testing) and a track record of solving complex process problems with data-driven approaches in a fast-paced

Qualifications

• PhD, MS (3+ yrs) or BS (5+ yrs) in a related field with batteries focus
• Experience diagnosing assembly-related failures with advanced characterization
• Ability to translate process requirements into tooling specifications
• Strong data-driven problem solving and experimental design skills
• Effective cross-functional communication across engineering, quality, and management

Responsibilities

• Develops and refines cell assembly processes for solid-state batteries, including electrode handling, lamination, stacking, and pouch sealing
• Defines tooling and fixture requirements for assembly operations with engineers
• Characterizes process parameters to set specs and improve yield
• Applies metrology and electrochemical techniques to assess assembly quality and diagnose failures
• Develops QA/QC protocols and acceptance criteria for finished cells
• Leads root-cause investigations and corrective actions
• Collaborates with upstream/downstream teams to align assembly with material and performance needs
• Contributes to scale-up plans and manufacturing transfer readiness
• Maintains safety and adheres to best-practice updates

Skills

Cell assembly troubleshooting

Tooling specifications

Metrology & characterization

Experiment design & data analysis

Cross-functional communication

Education

Engineering degree (PhD/MS with 3+ yrs or BS with 5+ yrs) in Materials Science/Engineering/Physics

Tools

X-ray imaging

Electrochemical impedance spectroscopy

Job description

About Blue Current

Blue Current (the “Company”) is the industry leader in the development of silicon solid state batteries. Free of flammable liquid electrolytes, Blue Current’s fully dry, inherently safe batteries significantly reduce risks to human and environmental health while providing a higher-performance alternative to traditional lithium-ion batteries. Blue Current’s silicon-based platform is highly adaptable, enabling a cost-effective solution for both the mobility and stationary storage markets. Blue Current’s team works out of its state-of-the-art headquarters and pilot line facility in Hayward, California. To learn more about Blue Current, Inc., visit bluecurrent.com.

Position Summary

The Senior Cell Assembly Engineer is responsible for developing and refining the cell assembly processes at the core of Blue Current's solid-state battery technology, where the novelty of the cell design and formulation means that innovation is a routine part of the job rather than an exception. This engineer owns the assembly process from receipt of dry electrode rolls through finished cell delivery, defining the tooling requirements that mechanical and equipment engineers build to, and applying a sophisticated quality toolkit (visual inspection, layer alignment and tolerancing, X-ray imaging, and electrochemical characterization) to ensure that every cell meets defined structural and performance standards. Working across electrode process, cell engineering, mechanical engineering, and quality teams, the Senior Cell Assembly Engineer is a central integration point where materials, processes, and measurements come together. Success means a cell assembly process that produces high-quality, well-characterized cells consistently today, with the process understanding in place to support scale-up.

Essential Functions & Responsibilities

• Develops and refines cell assembly processes for solid-state batteries, including electrode handling and punching, alignment, lamination, stacking multiple layers, sealing pouches and tabs, and delivering finished products to the cell test team
• Defines tooling and fixture requirements for cell assembly operations, working closely with mechanical and equipment engineers to specify, validate, and iterate on tooling that meets process needs
• Characterizes assembly process parameters and their relationship to cell structural and electrochemical outcomes, building the process understanding needed to set specifications and improve yield
• Applies advanced metrology techniques including X-ray imaging, electrochemical characterization, and electrochemical testing to evaluate assembly quality and diagnose process failures
• Develops and monitors assembly-stage QA/QC protocols in partnership with the Quality team, including visual inspection criteria, edge alignment and layer tolerancing standards, and acceptance criteria for finished cells
• Leads root cause investigations on assembly defects and cell failures attributable to assembly process, implementing and documenting corrective actions
• Collaborates with electrode process and cell engineering teams to ensure assembly process decisions account for upstream material and electrode constraints and downstream cell performance requirements
• Contributes to scale-up planning by identifying critical assembly process parameters and tooling requirements that must be addressed on the path to high-volume manufacturing
• Leads projects by developing clear, actionable plans with defined milestones and success metrics, managing timelines effectively, and ensuring high-quality, on-schedule execution
• Supports a strong safety culture by following and improving laboratory safety practices, demonstrating exemplary experimental techniques, and helping implement best-practice updates
• Other duties as assigned, consistent with the scope and level of this position

Minimum Qualifications

Education

• PhD, MS (with 3+ years of relevant experience), or BS (with 5+ years of relevant experience) in Materials Science, Chemical Engineering, Chemistry, Physics, or a related field, with a focus on batteries or electrochemical devices

Experience

• Experience troubleshooting and diagnosing assembly-related failures using advanced characterization techniques such as X-ray imaging or electrochemical impedance spectroscopy, going beyond visual inspection to identify root causes
• Experience translating process requirements into tooling or fixture specifications, and working iteratively with engineers to validate that the resulting hardware meets process needs

Skills & Knowledge

• Sufficient understanding of solid-state or lithium-ion battery electrochemistry to interpret characterization data in the context of assembly process decisions
• Ability to design experiments, analyze results, and draw data-driven conclusions in the absence of established reference points
• Ability to communicate process findings and recommendations clearly to colleagues across engineering, quality, and management functions

Certifications / Licenses

• N/A

Preferred Qualifications

• Hands-on experience with the full assembly sequence or meaningful portions of it, including electrode handling, lamination, layer stacking, and pouch sealing, with personal accountability for process outcomes rather than execution within a defined SOP
• Prior experience with solid-state battery assembly specifically, including familiarity with the unique challenges of handling and assembling solid-state electrodes
• Experience with dry room or controlled environment assembly processes, including familiarity with the operational constraints and material handling requirements those environments impose
• Familiarity with designing and using manual assembly tooling, and then translating learnings to automated or semi-automated assembly equipment. This should include experience contributing to equipment specification or process transfer from manual to automated operations
• Experience contributing to cell assembly scale-up efforts, including identifying critical process parameters and documenting process knowledge in a form that supports future manufacturing transfer
• Background in structured problem-solving methodologies such as PFMEA, with experience applying them to novel or poorly-characterized processes
• Experience working with manufacturing execution systems (MES) or similar production data platforms, including participation in their development or implementation

Core Values

• Safety & Security First — Demonstrated commitment to maintaining a safe and secure work environment, including adherence to workplace safety protocols, data privacy standards, and confidentiality requirements. Demonstrated ability to identify and appropriately escalate potential risks to personnel, customers, or sensitive information.
• Trust & Respect — Treat everyone with honesty, dignity, and sensitivity. Embrace different perspectives. Be humble. Demonstrated ability to communicate and collaborate effectively with individuals of diverse backgrounds, perspectives, and working styles.
• Ownership & Accountability — Take responsibility and action. Set goals and deliver. Don’t wait for others. Demonstrated ability to independently prioritize, execute, and follow through on responsibilities with minimal supervision.
• Technical Excellence — Always strive for the best solution possible. Demonstrated commitment to quality and continuous improvement in delivering work product, solutions, and outcomes within area of expertise.
• Learn & Be Curious — Think outside the box. Always learning. Demonstrated ability to quickly acquire new skills, tools, or domain knowledge in response to evolving business needs.
• Be Resourceful — Be hungry, frugal, and flexible. Use what you have. Find a way. Demonstrated ability to deliver results in resource-constrained environments by maximizing existing tools, processes, and partnerships.
• Delight Customers — Build stronger relationships with internal and external customers. Demonstrated commitment to understanding and exceeding the needs of internal and/or external customers.

Physical Requirements & Working Conditions

• Able to pass a respirator fit test and wear a respirator periodically.
• Regularly works in an active manufacturing and laboratory environment; standing and walking for a significant portion of the workday (approximately 4-6 hours per day)
• Frequent interaction with process equipment, requiring manual dexterity and the ability to make detailed visual inspections of materials and coated electrodes
• Occasional lifting of items up to 30 lbs (e.g., material containers, equipment components)
• Prolonged periods of screen-based work for data analysis, documentation, and communication
• Regular use of personal protective equipment (PPE) including safety glasses, gloves, and lab coat; additional PPE may be required depending on materials handled
• Travel is estimated at less than 10% of working time. Overseas travel is possible in the event of FAT program execution or in the event of vendor or supplier visits.

Salary Range: $111,600 — $160,000 USD

Equal Opportunity Employment Statement

Blue Current is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, veteran status, age, or any other characteristic protected by applicable federal, state, or local law.

At-Will Employment & Disclaimer

Employment at Blue Current is at-will. This means that either the employee or Blue Current may terminate the employment relationship at any time, for any reason or no reason, with or without cause, and with or without advance notice, subject to applicable law. This job description does not create an express or implied contract of employment, nor does it alter the at-will nature of the employment relationship. The duties, responsibilities, and qualifications described herein are subject to change at the Company's discretion and do not represent all tasks that may be required of this role.

Applicants must be authorized to work in the U.S. without the need for sponsorship now or in the future.