Senior Lithium Process Engineer

Lyten, Inc.; United States; On-site; USD 128,000 - 192,000; Full time

Job summary

Lyten, Inc. is hiring a Senior Lithium Process Engineer to lead the development and optimization of Lithium foil manufacturing from lab to full production.

You will drive DOE/ SPC improvements and manage extrusion and rolling mill operations to achieve tight thickness and edge quality targets. The role requires hands-on experience with metal extrusion and rolling mill equipment, handling reactive alkali metals, and strong problem-solving skills.

Qualifications

• Master’s degree in engineering or related field with 3+ years of experience OR bachelor’s with 5+ years in Materials Science, Chemical Engineering, Chemistry, or related field.
• Solid understanding of Roll-to-Roll manufacturing processes.
• Hands-on experience operating or troubleshooting metal extrusion and/or rolling mill equipment.
• Experience handling reactive, air‑sensitive, or hazardous materials in manufacturing.
• Experience handling alkali metals (Lithium/Sodium).
• Knowledge of DOE, SPC, and process capability analysis.
• Strong root cause analysis and problem-solving skills.
• Excellent documentation skills (SOPs, work instructions, process specs).
• Ability to work cross-functionally in a fast-paced environment.

Responsibilities

• Own development and optimization of Lithium foil manufacturing processes, from lab to full production scale.
• Lead DOE and SPC efforts to improve extrusion and rolling mill consistency and yield.
• Operate extruder and rolling mill to produce lithium foils with precision.
• Control process parameters to hit target specifications.
• Troubleshoot extrusion defects and rolling defects.
• Set up inspection methods and control limits for thickness/edge quality.
• Lead root cause analysis and yield improvement across the line.
• Collaborate with vendors and write SOPs and PFMEA.

Skills

R2R manufacturing

DOE/ SPC analysis

Root cause analysis

Troubleshooting extrusion/rolling

Cross-functional collaboration

Documentation

Education

Master’s degree in Engineering

Bachelor’s degree with 5+ years experience

Tools

Roll-to-Roll system

Extruder

Rolling mill equipment

Job description

Lyten is leading an industrial revolution through Lyten 3D Graphene™, a breakthrough supermaterial unlocking a new generation of products — from lithium–sulfur batteries and energy storage systems to concrete admixtures, lightweight composites, and next‑generation sensors that are revolutionizing industries. Together, these innovations are making a massive global improvement and driving real‑world impact across energy, mobility, construction, and defense. At Lyten, we believe the most meaningful careers begin with purpose — and with people who want to make a difference. We’re not just developing advanced supermaterials — we’re about to change the world as we know it, reshaping how energy is stored, how products are built, and how progress is made. We’re entering an exciting growth phase, scaling production across the U.S. and Europe and expanding our team of engineers, scientists, and innovators.

Senior Lithium Process Engineer

Key Responsibilities

• Own development and optimization of Lithium foil manufacturing processes, from lab to full production scale.
• Lead DOE and SPC efforts to improve extrusion and rolling mill consistency and yield.
• Operate extruder and rolling mill by extruding bulk lithium into strips to precision milling them into thin foils on a Roll‑to‑Roll (R2R) system.
• Control hydraulic pressure, barrel/die temperature zones, and extrusion speed to hit target spec.
• Troubleshoot extrusion defects — surface tearing, dimensional drift, inconsistent feed rate.
• Control Rolling mill roller gap, force, speed, and tension through the line to hit production quality targets.
• Manage roll conditions to prevent sticking, tearing, or edge cracking of lithium.
• Troubleshoot rolling defects — thickness variation, pinholes, wrinkling, edge cracks, surface scoring.
• Set up inspection methods and control limits for thickness and edge quality.
• Lead root cause analysis and troubleshooting for defects and yield losses across the line.
• Select and validate process equipment and work with vendors.
• Write and maintain SOPs and process specs and roll out PFMEA.

Required Qualifications

• Master’s degree with 3+ years of relevant experience OR bachelor’s degree in electrical, Mechanical, Chemical Engineering, or related field AND 5+ years of relevant experience in Materials Science, Chemical Engineering, Chemistry, or a related field.
• Solid understanding of R2R manufacturing processes
• Hands‑on experience operating or troubleshooting metal extrusion and/or rolling mill equipment.
• Experience handling reactive, air‑sensitive, or hazardous materials in a manufacturing setting.
• Experience handling alkali metals (Lithium/Sodium)
• Working knowledge of DOE, SPC, and process capability analysis
• Strong root cause analysis and problem‑solving skills
• Excellent documentation skills (SOPs, work instructions, process specs)
• Ability to work cross‑functionally in a fast‑paced environment

Preferred Qualifications

• Direct hands‑on experience operating or troubleshooting metal extrusion and/or rolling mill equipment on lithium or other alkali/soft metals.
• Knowledge of hydraulics and high‑pressure systems
• Experience leading technology transfer from pilot line to high‑volume production
• Familiarity with PLC/automation controls for extrusion or rolling equipment

Physical Requirements

Must be able to lift 50 lbs.

Compensations

• Range: The expected base salary range for this position is between $128,200.00 - $192,400.00 The level of pay within the range will depend on a variety of job‑related factors that may include location, relevant prior experience and/or education, or particular skills and expertise.
• Pay Transparency Disclosure: This compensation and benefits information is based on Lyten’s estimate as of the date of publication and may be modified in the future. We generally do not negotiate on salary once we have made an offer. The level of pay within the range will depend on a variety of job‑related factors that may include location, relevant prior experience and/or education, or particular skills and expertise. New hires joining the company tend to be paid within the starting base pay range noted above, with opportunities to increase pay over time based on development of additional skills, competencies, and company‑specific knowledge. In addition to base pay this position is eligible for tier‑based bonus and equity, healthcare, dental, vision, corporate discounts, paid holidays, PTO and sick time, 401K, employee relocation plan (if applicable).

Disclosures

Export/ITAR Compliance Disclosure: Certain positions within Lyten, Inc. require compliance with export control laws and, as a result, all interviewed candidates will be screened pre‑interview to determine their eligibility in light of export restrictions. This position requires access to technology, software and other information that is subject to governmental access control restrictions, due to export controls. Employment in this position is conditioned on the continued availability of government authorization to authorize release of such items, to the extent required, including without limitation an export license, or other documentation required to establish authorization to receive access to such items. Company may delay commencement of employment, rescind an offer of employment, terminate employment, and/or may modify job responsibilities, compensation, benefits, and/or access to Company facilities and information systems, as Company deems appropriate, in order to ensure compliance with applicable government access control restrictions.

Lyten is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, religion, color, national origin, sex, age, status as a protected veteran, or status as a qualified individual with a disability. EEO Employer/Vet/Disabled.

Why Work at Lyten

At Lyten, you’ll be part of a team that’s redefining what’s possible in energy, materials, and manufacturing. We’re not just imagining the future — we’re building it today with breakthrough technologies that are changing how products are made and how industries innovate. Our people are the heart of that mission. From world‑class scientists and engineers to creative problem‑solvers in operations, manufacturing, and commercialization, every member of the Lyten team plays a role in turning bold ideas into real‑world impact. We believe that the best work happens when you’re doing great things in the world — with people you like. Collaboration, curiosity, and a shared sense of purpose drive everything we do.

What You’ll Find at Lyten

A mission that matters: Contribute directly to solving complex challenges in energy, mobility, and materials innovation. Cutting‑edge innovation: Work on technologies at the intersection of materials science, energy storage, and advanced manufacturing that strengthen energy security and local supply chains. Extraordinary people: Join a team of talented, friendly, and down‑to‑earth innovators who support, challenge, and inspire one another every day. Teamwork and culture: Experience a workplace built on trust, respect, and shared success — where collaboration fuels breakthroughs and everyone’s ideas are heard. Global impact: Help scale new materials and energy solutions that reinforce industrial resilience across the U.S. and Europe. Career growth: Be part of a fast‑moving company entering a commercial growth phase, with opportunities to lead, learn, and make your mark. Purpose‑driven values: Thrive in an environment that celebrates ingenuity, optimism, and meaningful progress — together.

Lyten offers the opportunity to do the most important work of your career — helping build the technologies that will power the next century of innovation. Join us, and help transform industries, communities, and the planet with friends who share your drive to make a difference.

Founded in 2015 in Silicon Valley, California, Lyten is transforming the future of energy and materials innovation to build a stronger, more resilient world. Our breakthrough innovation, Lyten 3D Graphene™, is a brand‑new supermaterial that enables the creation of products that perform better and cost less. Lyten is rapidly scaling operations across the U.S. and Europe. Our lithium‑sulfur (Li‑S) batteries—free from nickel, manganese, cobalt, and graphite—deliver higher energy density and lighter weight while enabling a more secure, independent supply chain and a next‑generation alternative to traditional lithium‑ion chemistry. The acquisition of Northvolt’s assets in California, Poland, Sweden, and Germany has established a strong foundation for Lyten’s global energy storage growth, including Europe’s largest Battery Energy Storage System (BESS) manufacturing facility. Beyond battery systems, Lyten’s platform technology extends to high‑performance concrete admixtures, advanced composites, adhesives, and sensors, redefining material performance across industries from automotive and aerospace to construction and defense. Lyten has raised over $625 million in equity and received support from the U.S. Export‑Import Bank to provide up to $650 million in financing for international customer energy storage projects. Recognized as one of Fast Company’s “Most Innovative Energy Companies,” one of TIME’s “Top Green Technology Companies,” and a Silicon Valley Defense Group Top 100 National Security Company, Lyten is leading the next wave of high‑performance materials and energy systems that enhance energy security and supply chain resilience. Our lithium‑sulfur batteries have been selected to power Chrysler’s Halcyon Concept EV. Behind every Lyten innovation is a world‑class team of scientists, engineers, and business leaders from some of the most respected technology, energy, and manufacturing companies — all united by a shared mission to make a lasting global impact. We’re entering an exciting growth phase — expanding production, launching new products, and hiring exceptional talent across engineering, operations, manufacturing, and commercialization. If you’re ready to shape the next era of advanced materials and product innovation — while working alongside some of the brightest minds in science and engineering — join Lyten and help us build the next industrial revolution.