Senior Manufacturing Engineer - Assembly, Laser & Material Handling

Senior Manufacturing Engineer (IC)

Ensurge Micropower is a pioneer in solid-state microbattery technology, enabling the next generation of intelligent, connected devices. Leveraging proprietary thin-film and roll-to-roll manufacturing, Ensurge delivers safe, high-energy-density batteries for wearables, health tech, industrial sensing, and defense applications. As our technology transitions from development to production, disciplined manufacturing execution becomes the differentiator.

Role Overview: Ensurge is seeking a Senior Manufacturing Engineer (IC) to own and scale the Assembly, Laser, and Material Handling processes from pilot through early production.

This role is not just about process — it is about delivering manufacturing results.

You will be responsible for:

• Turning engineering processes into production-capable systems
• Driving output, yield, and stability on the line
• Building the infrastructure (process, equipment, flow, documentation) required for repeatable execution

This is a high-impact, hands-on role at the center of Ensurge's transition from technology demonstration to product delivery.

Key Responsibilities

Manufacturing Ownership & Output

• Own daily manufacturing performance for the Assembly, Laser, and Material Handling areas
• Drive output, yield, uptime, and cycle time
• Support production directly — troubleshooting issues in real time
• Partner with Operations to ensure line execution meets plan

Process to Production Conversion

• Convert R&D processes into repeatable, production-ready workflows
• Define and lock:
• Process flows
• Critical parameters (CPPs)
• Control limits and OCAPs
• Ensure processes are robust, stable, and scalable

Equipment & Line Readiness

• Work with Equipment Engineering to:
• Define tool requirements
• Improve reliability and uptime
• Implement process-driven upgrades
• Lead tool qualification and process acceptance
• Ensure equipment supports throughput, precision, and repeatability

Hardware & Automation (Strong Plus)

• Design or influence:
• Fixtures
• Handling systems
• Assembly tooling

Material Flow & Manufacturing System Design

• Own flow from sheet → quad → final assembly
• Reduce bottlenecks, WIP, and inefficiencies
• Improve line balance and production scheduling alignment
• Support layout and flow improvements as the system scales

Quality, Control & Documentation

• Partner with Quality to implement:
• SPC and process control
• Traceability and data capture
• Build and maintain :
• SOPs
• Process specs
• Control plans
• Ensure manufacturing is data-driven and auditable

Problem Solving & Continuous Improvement

• Lead structured RCA on:
• Yield loss
• Defects
• Downtime
• Implement sustainable fixes — not workarounds
• Drive continuous improvement aligned to operational excellence principles (standard work, DMS, etc.)

What We're Looking For

• 7–12+ years in manufacturing engineering (battery, semiconductor, thin-film, or similar)
• Proven experience owning manufacturing processes on the floor
• Strong track record of:
• Driving yield and throughput improvements
• Supporting or leading pilot → production scale-up
• Hands-on mindset — comfortable working directly with:
• Equipment
• Technicians
• Operators

Preferred Qualifications

• Experience with:
• Laser processing or micromachining
• Precision assembly or micro-scale systems
• Automated material handling
• Background in thin-film, semiconductor, or battery manufacturing
• Experience with MES, traceability systems, or data-driven manufacturing

Personal Attributes

• Ownership mentality — sees problems through to resolution
• Execution-focused — prioritizes results over theory
• Systems thinker — understands interactions across process, equipment, and flow
• Low ego, high accountability — works across teams to get things done
• Comfortable in a fast-moving, scaling environment

Salary Range: $161,626.00-$197,833.00

The base salary range is specific to California. The salary of the final candidate selected for this role will be determined by a variety of factors, including, but not limited to, internal equity, experience, education, specialty, and training.