About Blue Current
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
The Senior Electrode Process Engineer is responsible for producing finished electrodes that meet the quality and performance standards required by Blue Current's cell assembly team, while simultaneously developing the process knowledge needed to scale electrode manufacturing to high-volume production. This role covers the full electrode manufacturing process from slurry preparation through coating, drying, and calendering, with an emphasis on process characterization, yield improvement, and the establishment of robust QA/QC protocols developed in partnership with the Quality team. The Senior Electrode Process Engineer plays a central role in validating processes at current scale and defining the pathway to gigafactory-level production, ensuring that what works in the lab or pilot line is understood well enough to translate reliably at volume. Success means consistent, high-quality electrode delivery to the cell assembly team today, and a process foundation that is ready to scale tomorrow.
Essential Functions & Responsibilities
- Executes and refines electrode manufacturing processes across all unit operations including slurry mixing, coating, drying, and calendering, delivering finished electrodes to the cell assembly team that consistently meet defined quality specifications
- Evaluates, selects, and validates process equipment based on the specific rheological, chemical, and dimensional requirements of each electrode formulation. Examples may include selecting/validating mixer types (e.g., planetary, ball mill, homogenizer) and coating methods (e.g., slot die, comma, gravure).
- Characterizes process parameters and their relationships to electrode properties, building the process understanding needed to set specifications, tighten tolerances, and improve yield
- Develops and monitors QA/QC protocols in partnership with the Quality team, including inline and post-process inspection criteria, measurement methods, and acceptance standards for finished electrodes
- Identifies process failure modes and leads root cause investigations, implementing corrective actions and documenting outcomes to build institutional process knowledge
- Translates current pilot-scale process knowledge into scalable procedures, identifying critical process parameters and equipment requirements that must be addressed on the path to high-volume manufacturing
- Collaborates with cell engineering and materials teams to ensure electrode process decisions account for downstream cell assembly requirements and cell performance outcomes
- Leads projects by developing clear, actionable plans with defined milestones and success metrics, managing timelines effectively, and ensuring high-quality, on-schedule execution
- Supports a strong safety culture by following and improving laboratory safety practices, demonstrating exemplary experimental techniques, and helping implement best-practice updates
- Other duties as assigned, consistent with the scope and level of this position
Minimum Qualifications
Education
- PhD, MS (with 3+ years of relevant experience), or BS (with 5+ years of relevant experience) in Materials Science, Chemical Engineering, Chemistry, Physics, or a related field, with a focus on batteries or electrochemical devices
Experience
- Hands-on experience developing and optimizing slurry-based electrode manufacturing processes, including mixing, coating, drying, and calendering operations
- Track record of selecting and validating process equipment for a given set of material and process requirements, with working knowledge of multiple mixer and coater types
- Experience developing or operating QA/QC protocols in a manufacturing or process development environment, including defining specifications and measurement methods
- Experience working across functional teams, communicating process findings and recommendations to colleagues in adjacent disciplines such as cell engineering or materials science
Skills & Knowledge
- Working knowledge of slurry rheology and how mixing and coating process parameters influence electrode microstructure and final properties
- Proficiency with standard data analysis tools sufficient to process, visualize, and communicate process and quality data
Certifications / Licenses
- N/A
Preferred Qualifications
- Prior experience with solid-state or dry electrode manufacturing processes, including solvent-free or low-solvent coating approaches
- Familiarity with lithium-ion or solid-state battery cell architecture and how electrode properties such as porosity, loading, and thickness influence cell performance
- Experience contributing to process scale-up efforts, including equipment specification, process transfer documentation, or qualification runs at increased volume
- Background in failure analysis or structured problem-solving methodologies such as PFMEA or Six Sigma
- Familiarity with statistical methods for process characterization and control, such as design of experiments or statistical process control
- Familiarity with pilot-to-production process validation frameworks, including process capability studies or equipment qualification protocols
- Experience working with manufacturing execution systems (MES) or similar production tracking and data management platforms, including participation in their development or implementation
Core Values — Minimum Qualifications
Safety & Security First
For employees, customers, and intellectual property
- 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.
Trust & Respect
Treat everyone with honesty, dignity, and sensitivity. Embrace different perspectives. Be humble.
- 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.
Ownership & Accountability
Take responsibility and action. Set goals and deliver. Don't wait for others.
- 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.
Technical Excellence
Always strive for the best solution possible.
- 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.
Learn & Be Curious
Think outside the box. Always learning.
- 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.
Be Resourceful
Be hungry, frugal, and flexible. Use what you have. Find a way.
- 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.
Delight Customers
Build stronger relationships with internal and external customers.
- 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.
Physical Requirements & Working Conditions
- Able to pass a respirator fit test and wear a respirator periodically.
- Regularly works in an active manufacturing and laboratory environment; standing and walking for a significant portion of the workday (approximately 4-6 hours per day)
- Frequent interaction with process equipment, requiring manual dexterity and the ability to make detailed visual inspections of materials and coated electrodes
- Occasional lifting of items up to 30 lbs (e.g., material containers, equipment components)
- Prolonged periods of screen-based work for data analysis, documentation, and communication
- Regular use of personal protective equipment (PPE) including safety glasses, gloves, and lab coat; additional PPE may be required depending on materials handled
- Travel is estimated at less than 10% of working time. Overseas travel is possible in the event of FAT program execution or in the event of vendor or supplier visits.
Equal Opportunity Employment Statement
Blue Current is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, veteran status, age, or any other characteristic protected by applicable federal, state, or local law.
At-Will Employment & Disclaimer
Employment at Blue Current is at-will. This means that either the employee or Blue Current may terminate the employment relationship at any time, for any reason or no reason, with or without cause, and with or without advance notice, subject to applicable law. This job description does not create an express or implied contract of employment, nor does it alter the at-will nature of the employment relationship. The duties, responsibilities, and qualifications described herein are subject to change at the Company's discretion and do not represent all tasks that may be required of this role.
Applicants must be authorized to work in the U.S. without the need for sponsorship now or in the future.
Skills Required
- PhD, or MS with 3+ years relevant experience, or BS with 5+ years relevant experience in Materials Science, Chemical Engineering, Chemistry, Physics, or related field (focus on batteries or electrochemical devices).
- Hands-on experience developing and optimizing slurry-based electrode manufacturing processes including mixing, coating, drying, and calendering.
- Experience selecting and validating process equipment and working knowledge of multiple mixer and coater types.
- Experience developing or operating QA/QC protocols in a manufacturing or process development environment, including defining specifications and measurement methods.
- Experience working cross-functionally and communicating process findings to cell engineering and materials science teams.
- Working knowledge of slurry rheology and how mixing and coating parameters influence electrode microstructure and properties.
- Proficiency with standard data analysis tools sufficient to process, visualize, and communicate process and quality data.
- Able to pass a respirator fit test, wear a respirator periodically, use PPE, and perform physical tasks in a manufacturing/lab environment (standing, lifting up to 30 lbs).
- Authorization to work in the U.S. without the need for sponsorship now or in the future.
- Prior experience with solid-state or dry electrode manufacturing, solvent-free or low-solvent coating approaches.
- Familiarity with lithium-ion or solid-state battery cell architecture and electrode property impacts on cell performance.
- Experience contributing to process scale-up, equipment specification, process transfer documentation, or qualification runs at increased volume.
- Background in failure analysis or structured problem-solving methodologies such as PFMEA or Six Sigma.
- Familiarity with statistical methods for process characterization and control (DOE, SPC).
- Familiarity with pilot-to-production validation frameworks, process capability studies, or equipment qualification protocols.
- Experience with Manufacturing Execution Systems (MES) or similar production tracking and data management platforms.
What We Do
Blue Current manufactures silicon elastic composite solid-state batteries for EVs and non-automotive device applications. Blue Current leads with science, data and thoughtful IP across the full solid-state battery solution stack.
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