Sr. Process Engineer

Blue Current•Hayward, CA

About The Position

Blue Current (the “Company”) 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, California. To learn more about Blue Current, Inc., visit http://bluecurrent.com. Position Summary Blue Current is seeking a hands-on Senior Process Engineer for developing formulation and coating processes for next generation separators used in Blue Current’s solid-state batteries. The ideal candidate will have a background in formulation, coating and characterization in the battery or adjacent industry (fuel cell/ solar/ electronic materials, etc). Additional experience in electrochemistry of lithium-ion batteries is a bonus. The Senior Process Engineer will design and conduct experiments for prototyping and characterizing new separator formulations and architectures, and collaborate with the Cell Engineering and Advanced Manufacturing teams for qualifying through cell builds and scaling up to the pilot line. This is a highly cross-functional, hands-on and fast-paced position with a team of scientists and engineers that have a shared passion to change the energy storage landscape.

Requirements

PhD, MS (3+ years work experience), or BS (5+ years experience) in Materials Science, Chemical Engineering, Chemistry, Physics, or a related field, with a focus on batteries, capacitors, fuel cells, or other electrochemical devices
Experience in battery R&D, with a strong focus on lithium-ion or solid-state battery systems
Hands-on experience developing and scaling slurry-based processes, including mixing, coating, and drying
Proven experience planning, leading, and executing R&D projects, delivering results on schedule in fast-paced environments
Demonstrated experience collaborating cross-functionally with cell engineering, materials, and manufacturing teams
Strong understanding of separator materials, polymer/inorganic composites, and their role in solid-state or lithium-ion batteries
Expertise in slurry formulation, rheology, and coating science for thin-film materials
Familiarity with analytical and characterization tools such as SEM, XRD, TGA, FTIR, DSC, and related techniques
Experience with electrochemical testing techniques such as EIS, GITT, HPPC, CV, and related methods
Ability to analyze relationships between material properties, processing conditions, and cell performance
Strong data analysis and problem-solving skills, with a structured, hypothesis-driven approach
Excellent communication skills, with the ability to clearly present complex technical findings to cross-functional teams and leadership
Strong project management, organization, and prioritization skills
Demonstrated commitment to maintaining a safe and secure work environment, including adherence to workplace safety protocols, data privacy standards, and confidentiality requirements.
Proven ability to identify and appropriately escalate potential risks to personnel, customers, or sensitive information.
Demonstrated ability to communicate and collaborate effectively with individuals of diverse backgrounds, perspectives, and working styles.
Track record of maintaining professionalism, integrity, and discretion in all workplace interactions.
Demonstrated ability to independently prioritize, execute, and follow through on responsibilities with minimal supervision.
Proven track record of setting measurable goals, meeting deadlines, and taking initiative to resolve challenges proactively.
Demonstrated commitment to quality and continuous improvement in delivering work product, solutions, and outcomes within area of expertise.
Ability to evaluate options critically and apply sound judgment to identify the most effective and scalable solution.
Demonstrated ability to quickly acquire new skills, tools, or domain knowledge in response to evolving business needs.
Proven track record of applying creative or unconventional thinking to solve problems.
Demonstrated ability to deliver results in resource-constrained environments by maximizing existing tools, processes, and partnerships.
Proven ability to adapt and find effective solutions in ambiguous or rapidly changing situations.
Demonstrated commitment to understanding and exceeding the needs of internal and/or external customers.
Track record of building and maintaining strong, trust-based relationships that drive positive outcomes for all stakeholders.

Nice To Haves

Direct experience with solid-state battery systems and separator architectures
Experience transferring processes from lab-scale to pilot or manufacturing-scale equipment
Track record of innovation through patents, publications, or internal IP contributions

Responsibilities

Develop and test new materials, formulation, mixing and coating processes for separators that enable safe, high energy density solid-state batteries.
Characterize slurry and separator quality using rheological, mechanical, imaging and electrochemical techniques, and develop new characterization methods as needed.
Evaluating novel separator compositions and architectures in solid state cells. Analyze test results to understand the impact of separator properties on cell performance.
Partner with the Advanced Manufacturing team to transfer mixing and coating processes to manufacturing equipment.
Clearly communicate complex results to cross-functional teams and senior leadership.
Work with cross-functional teams ensuring high-quality, on-schedule execution of projects.
Continuously survey and interpret literature on solid-state battery materials and architectures, integrating key insights into the company’s technical strategies.
Contribute to the company's IP portfolio by exploring novel materials, cell designs, and processing approaches that advance solid-state cell performance
Support a strong safety culture by following and improving laboratory safety practices, demonstrating exemplary experimental techniques, and helping implement best-practice updates.

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