Process Development Engineer

Job Title: Senior / Principal Cell Engineer / Consultant— Prismatic Cell Development (Alsym is looking for full-time role or consultant roles for this position) Industry Background: Energy storage is one of the fastest-growing sectors in the global energy economy, with annual stationary storage capacity additions projected to grow 23% per year from 2025 to 2035, driven by surging electricity demand from electrification, data centers, and AI infrastructure. Alsym Energy is the leading developer of non-flammable, high-performance, low-cost sodium-ion batteries for AI data centers, utilities, commercial real estate and anywhere else energy storage is needed. Position Summary We are seeking a Senior or Principal Cell Engineer to lead the architectural definition, design specifications, and technology transfer of Alsym’s large-format prismatic cells. In this role, you will own the physical cell architecture end-to-end, translating our novel chemistry constraints into scaled, manufacturable prismatic form factors. You will serve as the technical lead for cell prototyping events, validation programs, supplier downs-election, and technology transfer to Tier-1 contract manufacturing partners. Key Responsibilities Prismatic Cell Architecture Ownership End-to-End Cell Design: Lead the physical architecture definition for Alsym's large-format sodium-ion prismatic cells. Ensure all internal design elements (e.g., jellyroll/stack configuration, current collectors, terminal tabs, venting, and enclosure) are optimized for performance and contract manufacturing scalability. Design Trade-off Optimization: Drive engineering trade-offs balancing energy density, mechanical stability, thermal runaway safety, manufacturability. Chemistry-to-Cell Translation: Own the translation of Alsym’s proprietary non-flammable chemistry requirements (electrodes, electrolytes, separator specs) into rigorous cell-level engineering specifications. Prototyping Ownership: Plan, lead, and evaluate prismatic cell prototyping builds—from initial laboratory-scale samples through prototype line builds—iterating quickly based on empirical data. Competitive Intelligence: Lead Alsym’s competitive benchmarking program for Tier-1 prismatic cell formats (Li-ion, Na-ion, LFP) to maintain an in-depth understanding of state-of-the-art cell designs, packaging, and manufacturing trends. Strategic Recommendations: Translate competitive teardown and testing insights into actionable design improvements for internal engineering teams and executive leadership. Supplier & Partner Down-selection: Collaborate with external partners, Tier-1 suppliers, and contract manufacturers to select suitable equipment, cell components, and manufacturing facilities for scaled prototyping and production. Validation Strategy: Define, own, and execute master cell validation plans encompassing electrical performance, mechanical robustness, structural integrity, and abuse/safety testing. Tech Transfer & Readiness: Lead manufacturing readiness assessments (MRA) and own the technology transfer package as prismatic designs transition from R&D into high-volume pilot and commercial production. Bill of Materials (BOM) Management: Partner closely with Supply Chain and Procurement to define, lock, and manage the complete cell BOM, ensuring alignment with cost targets, sourcing constraints, and quality standards. Qualifications Education: Bachelor’s, Master’s, or Ph.D. in Mechanical Engineering, Chemical Engineering, Materials Science, Electrochemical Engineering, or related field. Experience: Senior Level: 5+ years of direct experience in battery cell engineering, design, and manufacturing integration (preferably in prismatic formats). Principal Level: 8+ years of industry experience leading cell architecture projects, tech transfers, or Tier-1 supplier qualifications for large-format prismatic cells. Technical Expertise: Demonstrated track record of bringing a prismatic cell format from early-stage concept/prototyping through pilot production or high-volume manufacturing. Deep knowledge of prismatic cell manufacturing processes (slurry preparation, coating, winding/stacking, tab welding, assembly, electrolyte filling, and formation). Hands-on expertise with mechanical design tools (CAD: SolidWorks/NX) and battery modeling tools (FEA/CFD). Strong familiarity with design-for-manufacturability (DFM), DFMEA, and statistical process controls (SPC). Skills & Abilities: Proven ability to work cross-functionally between materials science/chemistry teams, equipment vendors, and supply chain partners. Strong technical communication skills with a track record of presenting complex trade-offs to senior leadership. Preferred Qualifications Direct experience with LFP, sodium-ion, polyanionic, or aqueous/non-flammable battery chemistries. Experience qualifying cells with Tier-1 automotive or stationary energy storage system (BESS) customers. Prior experience managing technical transfers with global Contract Manufacturers (CMs) or Joint Ventures (JVs). Compensation, Benefits, and Perks: We are committed to providing equitable compensation and a healthy working environment for our employees with a benefits package that provides the support that you need. premium medical insurance cost through Blue Cross Blue Shield dental insurance through Bento Dental flexible Paid Time Off program firm Anti-Harassment Policy that includes Diversity, Inclusion, Equity, & Gender Protections PFML, 401k, and stock options A full listing of our benefits may be provided after an offer has been issued. We are an equal opportunity employer and value diversity & inclusion at our company. We do not discriminate on the basis of race, religion, color, national origin, gender, sexual orientation, age, marital status, veteran status, or disability status. #J-18808-Ljbffr