Senior Cell Design Engineer

Sion Power Corporation; Tucson (AZ); On-site; USD 120,000 - 170,000; Full time

Job summary

Sion Power Corporation in Tucson, AZ, is seeking an experienced engineer to advance next-generation lithium-metal cells for automotive, defense, and consumer electronics. The role covers cell design, material development, and support for product launches.

You will define and execute DOE studies, qualify materials, and work with manufacturing to scale processes while maintaining high energy density and safety targets.

Qualifications

• 5+ years of professional experience in lithium battery cell development.
• Experience with design for manufacturability (DFM) and scaling cells.
• Proven ability to drive DOE studies and analyze results.
• Hands-on experience with electrochemical characterization techniques.
• Experience developing and controlling material specifications and PCBA types.

Responsibilities

• Lead planning and execution of lithium metal cell development with emphasis on DFM and scalability.
• Select, qualify, and validate cell materials and components (cathode, anode, electrolyte, separator, current collectors).
• Perform DOE to support fabrication, process optimization, and testing.
• Analyze data to identify failure modes, perform root-cause analysis and implement corrective actions.
• Provide hands-on support to manufacturing teams to resolve yield and quality issues in pilot runs.

Skills

Lithium metal chemistry

Electrochemistry

Design of Experiments (DOE)

DFMEA & PFMEA

Statistical analysis

Cell design & development

Formation processes

Data analysis

Education

Master's or PhD in Chemistry / Electrochemistry / Materials Science / Chemical Engineering

Tools

Minitab

Job description

Sion Power Corporation, based in Tucson, AZ, is the leading developer of high-energy rechargeable lithium‑metal battery technology, with more than 20 years of research and development. Years of research and development have yielded the Licerion® lithium metal technology, poised to dramatically change the lithium battery landscape by delivering the highest combination of energy density and specific energy.

Position Overview

This position will develop next-generation cells using advanced materials for automotive, defense, and consumer electronics applications as a key member of the Cell Engineering group. The successful applicant will develop, validate, and commercialize this innovative cell based on state-of-the‑art commercial and proprietary materials. The responsibilities of this position cover cell design, analysis, material development, and support for product launch.

Responsibilities

• Lead the planning and execution of lithium metal cell and electrode development with a strong focus on Design for Manufacturability (DFM) and scalability.
• Select, characterize, qualify, and validate cell materials and components, including cathode, anode, electrolyte, separator, and current collectors.
• Cell balancing with proprietary anode, matching cathode, and other key components for high performance cell
• Design, develop, and optimize proprietary anode architectures to achieve high‑performance cell metrics (energy density, cycle life, safety, and cost).
• Define, plan, and execute statistically robust Design of Experiments (DOE) to support cell fabrication, process optimization, and electrochemical testing.
• Analyze experimental and production data to identify performance trends and failure mechanisms; perform root‑cause analysis and implement corrective actions using DFMEA and PFMEA methodologies.
• Develop and maintain detailed technical documentation, including material specifications, design requirements, test protocols, and engineering reports.
• Provide hands‑on engineering support to cell manufacturing teams to resolve yield, quality, and process‑related issues during pilot and production builds.
• Partner with Supply Chain and suppliers to develop, validate, and control material specifications for new and existing materials, and to address supplier‑related quality concerns.
• Support engineering‑level and pilot test builds in collaboration with quality, operations, and manufacturing teams to ensure successful design transfer and scale‑up.

Education/Experience

• Master's or PhD in Chemistry, Electrochemistry, Materials Science, Chemical Engineering, or a closely related field.
• Minimum of 10 years of industrial experience in the design, development, and commercialization of lithium rechargeable cells.
• Self‑motivated and accountable engineer with a strong sense of ownership and demonstrated ability to drive continuous improvement initiatives.
• Proven track record of successful design and development of lithium rechargeable cell components, assemblies, and formation processes.
• Hands‑on experience developing and managing technical specifications, component and assembly requirements, and quality tools including DFMEA and 8D problem‑solving.
• Demonstrated expertise in electrochemical characterization techniques, including cyclic voltammetry (CV), electrochemical impedance spectroscopy (EIS), cycle life testing, and abuse testing.
• Working knowledge of statistical analysis and Design of Experiments (DOE); experience with Minitab or similar statistical software preferred.