Senior Controls Engineer

AM Batteries; Billerica (MA); Hybrid; USD 130,000 - 175,000; Full time

Benefits offered by this job

Health insurance

Dental insurance

Vision insurance

Life insurance

Job summary

AM Batteries seeks a Senior Controls Engineer to lead design, development, and deployment of advanced control systems for next-generation lithium-ion battery manufacturing equipment. The role centers on hands-on engineering, cross-functional collaboration, and supporting industrialization of AMB technologies in a startup environment.

Responsibilities include PLC programming, SCADA and HMI work, motion control on roll-to-roll equipment, and integration with vendors and panel shops.

Qualifications

• 8+ years of experience in industrial controls and machinery automation.
• Proficiency with PLC programming and industrial automation hardware.
• Understanding of Ethernet/IP, Modbus, Profibus, and similar protocols.
• Experience with electrical schematics and control panel documentation.
• Knowledge of machine and electrical safety practices and lockout/tagout.
• Proven ability to troubleshoot real-world manufacturing equipment issues.
• Experience working with vendors and integrators.
• SQL databases for data storage and retrieval; Python for automation and data tasks.
• Strong communication and cross-disciplinary collaboration.
• Bachelor’s degree or higher in a relevant engineering field.

Responsibilities

• Convert heuristics into defined, tested automation that scales with production needs.
• Design, develop, program and maintain PLCs for complex automation.
• Configure and extend SCADA systems to support R&D, process development, and manufacturing operations.
• Develop and maintain HMIs for operation, diagnostics, and development workflows.
• Implement motion control on roll-to-roll equipment: servo setup, multi-zone tension, line speed synchronization, and registration.
• Collaborate with mechanical design and process engineers to define control requirements.
• Review electrical packages on machines: panel design, drives, protection, instrumentation, and sensors.
• Apply advanced control strategies to optimize performance, uptime, and process capability.
• Own controls integration with machine builders, integrators, and panel shops.
• Execute system testing, validation, commissioning, and startup for new equipment and pilot lines.
• Troubleshoot controls-related issues in deployed systems.
• Adhere to machine and electrical safety requirements and lockout/tagout procedures.
• Develop and maintain documentation for control designs and procedures.
• Keep code and drawings under version control and maintain records for patent support.
• Support SQL database integration and data collection for manufacturing and development.

Skills

PLC programming

Industrial automation hardware

Ethernet/IP

Modbus

Profibus

SQL databases

Python

Troubleshooting

Vendor management

Cross-functional collaboration

Safety systems

Education

Bachelor's degree in engineering

Tools

SCADA Ignition

HMI development

Siemens drives

Job description

AM Batteries is seeking a Senior Controls Engineer to play a key technical role in the design, development, and deployment of advanced control systems for next-generation lithium-ion battery manufacturing equipment. This role will support the industrialization of AMB’s proprietary technologies and contribute directly to the development of scalable, high-performance manufacturing platforms. AMB is a venture-backed startup moving this technology from R&D into commercial production.

The Senior Controls Engineer owns the design and delivery of control systems on assigned equipment, working within the architecture, programming, and documentation of company standards. The role works cross-functionally with mechanical engineering, process development, and operations teams. This role emphasizes hands-on engineering, technical problem solving, and field technical support while contributing to broader system reliability and performance.

Primary Roles & Responsibilities

Work with operators and process engineers to convert the heuristics they rely on today into defined, tested automation that scales.

Design, develop, program and maintain PLC programs for complex automation and controls systems to company standards

Configure and extend SCADA systems to support R&D, process development, and manufacturing operations

Develop and maintain HMIs to enable effective equipment operation, diagnostics, and development workflows

Implement motion and tension control on roll-to-roll equipment: servo setup and tuning, multi-zone tension, line speed synchronization, and registration.

Collaborate closely with mechanical design and process engineers to define control requirements and system specifications

Specify and review the electrical package on assigned machines: panel design, drives, protection, instrumentation, and sensor selection sized for the destination site, with component cost input for estimates.

Implement advanced control strategies to optimize equipment performance, uptime, and process capability

Own controls integration on assigned equipment, working with machine builders, integrators, and panel shops

Execute system testing, validation, commissioning, and startup activities for new equipment and pilot lines

Troubleshoot and resolve complex controls-related issues in deployed systems

Apply machine and electrical safety requirements in design and on the floor: guarding interlocks, safety-rated circuits, arc flash procedures, and lockout and tagout.

Develop and maintain documentation for control system designs, standards, and procedures

Keep code and drawings under version control, and maintain engineering records and invention disclosures that support AMB's patent program.

Support SQL database integration for manufacturing, process, and development data

Utilize Python (or similar languages) for automation, data analysis, and tool development

Provide technical mentorship and guidance to junior controls engineers

Basic Qualifications

8+ years of experience in industrial controls and machinery automation, including commissioning equipment and then supporting it in production for years afterward

Strong proficiency with PLC programming and industrial automation hardware

Solid understanding of industrial communication protocols (Ethernet/IP, Modbus, Profibus, etc.)

Experience working with electrical schematics and control panel documentation

Working knowledge of machine and electrical safety practice, safety-rated circuits, arc flash procedures, and lockout and tagout.

Proven ability to troubleshoot and resolve real-world manufacturing equipment issues

Experience working directly with equipment vendors and integrators

Component sizing and sourcing with distributors, and cost input for estimates and quotes.

Working knowledge of SQL databases for data storage and retrieval

Proficiency in Python or similar programming languages for automation and data tasks

Strong communication skills and ability to collaborate across disciplines

Bachelor’s degree or higher in a relevant engineering field

Preferred Qualifications

Experience with more than one PLC family, and with competing brands of drives, actuators, sensors, and safety devices. AMB equipment currently runs Siemens.

Experience with SCADA platforms (Ignition strongly preferred)

Hands-on experience with HMI development and interface design

Motion control experience: servos, drives, and coordinated axes. Web tension control is a strong plus.

Compensation

• Annual base salary range: $130,000-$175,000
• Health, dental, vision, and life insurance