Process Engineer - NMC Electrode Coating

EnerSys is a global leader in stored energy solutions for industrial applications. We have over thirty manufacturing and assembly plants worldwide servicing over 10,000 customers in more than 100 countries. Worldwide headquarters are located in Reading, PA, USA with regional headquarters in Europe and Asia. We complement our extensive line of Motive Power and Energy Systems with a full range of integrated services and systems. With sales and service locations throughout the world, and over 100 years of battery experience, EnerSys is the power/full solution for stored DC power products. 

Job Purpose

We are looking for a hands-on and highly motivated Process Engineer – Electrode Coating to support the development, optimization, and scale-up of lithium-ion battery electrode manufacturing processes. In this role, you will focus on roll-to-roll electrode coating and drying processes for cathode and/or anode electrodes, working closely with cell engineering, R&D, quality, production, maintenance, and equipment suppliers. This position requires specialized expertise in lithium-ion battery electrode manufacturing and will play a critical role in the industrialization, technology transfer, and startup of EnerSys' advanced battery Gigafactory operations.

Essential Duties and Responsibilities

• Develop, optimize, and stabilize electrode coating and drying processes for lithium-ion battery electrodes.
• Define and improve key process parameters such as coating gaps, pump rate, web speed, web tension, drying temperature profile, air flow, and solvent removal conditions.
• Support process transfer from laboratory scale to pilot line and production scale, ensuring robust manufacturability and reproducible electrode quality.
• Analyze and troubleshoot coating defects such as streaks, agglomerates, pinholes, edge defects, cracking, delamination, thickness variation, and poor adhesion.
• Plan, execute, and evaluate structured trials and design-of-experiments activities to improve process capability, yield, throughput, and product performance.
• Collaborate with slurry mixing, calendering, slitting, cell assembly, quality, and product engineering teams to ensure coating output meets downstream requirements.
• Define process windows, control plans, inspection criteria, and acceptance limits for coated electrodes.
• Support equipment commissioning, process validation, FAT/SAT activities, ramp-up, and continuous improvement projects.
• Create and maintain work instructions, SOPs, process specifications, trial reports, and technical documentation.
• Promote safe, clean, and disciplined operation of electrode coating equipment in line with EHS and quality standards.

Qualifications

• Bachelor’s or Master’s degree in Chemical Process Engineering, Materials Science, Mechanical Engineering, Process Engineering, or a related technical discipline.
• Relevant experience in electrode coating, roll-to-roll coating, thin-film coating, battery manufacturing, or a comparable high-precision production process.
• Good understanding of lithium-ion battery electrode manufacturing, including slurry behavior, coating, drying, calendaring, and electrode quality requirements.
• Experience with coating technologies such as slot-die, comma bar, doctor blade, or similar continuous coating processes.
• Ability to interpret process data, identify root causes, and implement effective corrective and preventive actions.

EnerSys provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.