Cell Process Engineer

Role details

Job Title: Cell Process Engineer

Electrovaya Inc. designs, develops, and manufactures proprietary lithium-ion batteries, battery systems, and battery-related products for energy storage, clean electric transportation and other specialized applications. Electrovaya is a technology focused company with extensive IP backing our proprietary lithium-ion battery technology, which provides an exceptional combination of safety, longevity, and energy density.

This position represents an exciting opportunity to be a part of ramping up operations in our new Jamestown NY manufacturing facility, contributing to the future of battery manufacturing and sustainable energy in North America. We are looking for ambitious candidates who are excited by the opportunity to be a part of a new team to develop a cutting manufacturing facility for high performance lithium-ion batteries.

Annual Salary: $100,000 - $115,000 per year

Key Responsibilities

Process Development and Optimization:

• Define and optimize pouch cell and module assembly processes including electrode handling, notching, stacking, welding, pouch formation and sealing, electrolyte filling, formation, and final inspection.
• Develop standard operating procedures (SOPs), work instructions, and process flow diagrams for all critical manufacturing steps.
• Implement lean manufacturing, Six Sigma, and DOE (Design of Experiments). methodologies to improve process stability and efficiency.
• Identify and mitigate process bottlenecks to achieve high yield and low defect rates.
• Lead process scale-up from pilot to production and support FAT/SAT activities

Cell Design & Development

• Own detailed cell design execution, including electrode sizing, stack design, tab configuration, tolerances, pouch forming and design-for-manufacturability considerations
• Develop and maintain cell-level BOMs, technical drawings, and specifications
• Support new cell development activities, design iterations, and engineering change management

Quality and Compliance:

• Develop and implement process control strategies to ensure consistent cell performance and reliability.
• Conduct root cause analysis (RCA) and corrective actions for quality defects such as delamination, electrolyte leakage, or tab welding inconsistencies.
• Work closely with the quality team to ensure compliance with ISO 9001, UL2580, and safety regulations.
• Utilize SPC (Statistical Process Control) and FMEA to identify and address process risks.
• Drive process capability improvements (Cp, Cpk) and yield optimization

Cross-functional Collaboration and Documentation:

• Collaborate with R&D, automation, and production teams to scale up new cell and module designs and manufacturing processes.
• Develop and maintain process documentation, including work instructions, troubleshooting guides, and technical reports.
• Train operators and technicians on best practices for process consistency and defect prevention.

Required Qualifications

and Skills

Technical Skills:

• Strong understanding of lithium-ion cell and module manufacturing processes.
• Hands-on experience with semi-automated cell and module assembly equipment.
• Expertise in cell design, process validation, statistical process control (SPC), and DOE (Design of Experiments).
• Proficiency in data analysis tools for process optimization.
• Knowledge of ISO 9001, and APQP (Advanced Product Quality Planning).
• Familiarity with material properties of lithium-ion components (electrolyte, separator, cathode/anode materials) and their impact on process parameters.

Soft Skills and Experience:

• Bachelor’s or Master’s degree in Chemical Engineering, Mechanical Engineering, Materials Science, or a related field.
• 5\+ years of experience in lithium-ion battery manufacturing industry.
• Strong problem-solving skills with a hands-on approach to process troubleshooting and optimization.
• Ability to work cross-functionally with engineering, production, and quality teams.
• Experience with FMEA, Lean, Six Sigma (Green Belt or higher preferred).

Preferred Experience:

• Hands-on experience in pouch cell production.
• Experience with semi-automated manufacturing lines and Industry 4.0 initiatives.
• Prior involvement in FAT, SAT, and commissioning of lithium-ion battery equipment.
• Experience in thermal management, gas formation control, and electrochemical performance testing.