Process Engineering Senior

Process Engineer
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.
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.
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.
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.
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.
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

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
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
Strong project management, organization, and prioritization skills
Experience transferring processes from lab-scale to pilot or manufacturing-scale equipment
Safety & Security FirstFor 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.
Demonstrated ability to independently prioritize, execute, and follow through on responsibilities with minimal supervision.Demonstrated commitment to quality and continuous improvement in delivering work product, solutions, and outcomes within area of expertise.Proven track record of applying creative or unconventional thinking to solve problems.
Be ResourcefulBe hungry, frugal, and flexible. Demonstrated ability to deliver results in resource-constrained environments by maximizing existing tools, processes, and partnerships.Delight CustomersBuild 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.
Required to wear personal protective equipment when applicable.
Able to work in an office, lab, and manufacturing environment with chemicals, moving mechanical parts, and electrical hazards.
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.
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.