Sr. Manager, Prototype Scaleup

Blue Current; Hayward (CA); On-site; USD 180,000 - 210,000; Full time

Job summary

Blue Current is seeking a seasoned Senior Manager, Early Scaleup to transition R&D solid-state battery processes into robust intermediate-scale manufacturing. You will mature electrode fabrication and cell assembly, define process windows, and establish scalable workflows, working with R&D, Cell Engineering, and Manufacturing to accelerate readiness for full-scale production.

The role requires 8+ years in battery manufacturing, hands-on tool experience, and strong leadership, project management,

Qualifications

• 8+ years in lithium-ion or solid-state battery manufacturing, process engineering, or scale‑up.
• Experience scaling processes from lab to pre-pilot or intermediate scale.
• Hands-on with equipment specification, installation, commissioning, and validation for semi-automated or early-scale tools.
• Ability to establish CTQs, SOPs, control plans, and quality metrics for reliable scaled operations.
• Strong leadership of engineering and technician teams in fast-paced hardware environments.
• Excellent analytical and problem-solving skills including DOE and structured problem-solving.
• Proven project management with cross-functional coordination and on-time delivery.
• Strong communication and documentation for handoff between R&D, Equipment, and Manufacturing.

Responsibilities

• Translate new R&D materials, cell designs, and processes into scalable intermediate‑scale manufacturing workflows.
• Develop and optimize scaled-up electrode processes (slurry, drying, calendaring) with defined process windows.
• Scale cell assembly operations (punching, stacking/winding, lamination, formation) for yield and throughput.
• Define scale-up roadmaps with milestones, timelines, and success metrics across teams.
• Own equipment strategy for early-scale processes including vendor selection and validation.
• Establish CTQs, SOPs, and quality controls for smooth pilot-line transfer.
• Lead root-cause analyses using DOE and statistical methods to resolve issues.
• Collaborate with R&D, Cell Engineering, Analytical, and Manufacturing to accelerate iteration.
• Mentor and develop engineering/tech teams; foster safety culture and training.

Skills

Leadership

DOE

Statistics

Project management

Data-driven decisions

Root-cause analysis

Communication

Safety culture

Education

BS/MS/PhD in Chemical Engineering, Materials Science, Mechanical Engineering or related field

Job description

About Blue Current

Blue Current 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, CA. To learn more about Blue Current, Inc., visit https://bluecurrent.com/.

Summary

Blue Current is seeking a highly experienced and hands‑on Senior Manager, Early Scaleup to lead the transition of R&D-developed solid-state battery processes into robust, intermediate-scale manufacturing. This role is pivotal in bridging the gap between lab innovation and pilot-line readiness by maturing electrode fabrication and cell assembly processes, defining process windows, and establishing reliable scaled workflows. The ideal candidate combines deep technical expertise with strong operational leadership, driving disciplined execution, rapid iteration, and data‑driven decision‑making. The candidate will collaborate closely with R&D, Cell Engineering, and Manufacturing teams to accelerate technology readiness and ensure a smooth pathway toward full‑scale production.

Key responsibilities

• Lead a team of engineers and technicians responsible for translating new R&D materials, cell designs, and processes into robust, repeatable, and scalable intermediate‑scale manufacturing workflows across electrode fabrication and cell assembly.
• Develop and optimize scaled‑up electrode processes, including slurry formulation, mixing, tape casting or dry processing, drying, and calendaring, ensuring stable operation, defined process windows, and strong correlation to both R&D and pilot‑line requirements.
• Scale cell assembly operations such as electrode punching, stacking or winding, lamination, and formation/conditioning, driving improvements in yield, consistency, and throughput.
• Define and execute scale‑up roadmaps, setting clear deliverables, timelines, and success metrics while coordinating resources across equipment, materials, analytical, and manufacturing teams.
• Own equipment strategy for early‑scale processes, including specification, vendor selection, installation, commissioning, and validation of semi‑automated or small‑format tools.
• Establish CTQs, process windows, SOPs, and quality controls to ensure reliable operation and smooth transfer of maturing processes to the pilot line.
• Lead root‑cause analyses and structured problem‑solving efforts, using DOE, statistical analysis, and failure analysis tools to resolve yield, performance, and equipment‑related issues.
• Collaborate closely with R&D, Cell Engineering, Analytical, and Advanced Manufacturing to align process requirements, ensure manufacturability, and maintain tight feedback loops that accelerate technology iteration.
• Build and develop a high-performing engineering and technician team, providing mentorship, technical guidance, and strong operational leadership.
• Champion a strong safety culture, ensuring safe scaling of materials, processes, and equipment while continuously improving safety protocols and training.

Requirements

• BS/MS/PhD in Chemical Engineering, Materials Science, Mechanical Engineering, or related discipline, with 8+ years of industry experience in lithium-ion or solid-state battery manufacturing, process engineering, or scale‑up.
• Demonstrated expertise in scaling battery processes from lab-scale to pre-pilot or intermediate scale, including slurry mixing, dry processing, drying, calendaring, punching, stacking, winding, lamination, pouching, and formation.
• Hands‑on experience with equipment specification, installation, commissioning, and validation, particularly for semi-automated or custom early‑scale tools.
• Proven ability to establish process windows, CTQs, SOPs, control plans, and quality metrics that enable reliable and repeatable scaled operations.
• Strong leadership experience, including managing and developing engineering and technician teams in a fast-paced, hardware-centric environment.
• Excellent analytical and problem‑solving skills, with proficiency in DOE, statistical analysis, root‑cause troubleshooting, and structured problem‑solving methodologies.
• Exceptional project management capabilities, including roadmap creation, milestone definition, cross‑functional coordination, and on‑time delivery of complex technical programs.
• Strong communication and documentation skills, with the ability to work closely with R&D, Equipment Engineering, Cell Engineering, Analytical, and Manufacturing to ensure smooth process handoff and rapid iteration cycles.
• Deep commitment to safety, with experience developing or enforcing safe operating procedures for battery materials, chemicals, and equipment.

Physical Demands and Work Environment

• Required to wear personal protective equipment when applicable.
• Able to pass a respirator fit test and wear a respirator periodically.
• Able to work in an office, lab, and manufacturing environment with chemicals, moving mechanical parts, and electrical hazards.

Salary Range: $180,000 — $210,000 USD

Blue Current is committed to Equal Employment Opportunity and embraces diversity. We believe that our team is strengthened through hiring and retaining employees with diverse backgrounds, skill sets, ideas, and perspectives. We make hiring decisions based on merit and do not discriminate based on race, color, religion, national origin, sex or gender (including pregnancy) gender identity or expression (including transgender status), sexual orientation, age, marital, veteran, disability status or any other protected category in accordance with applicable law.