Process Engineering Senior

Senior Process EngineerGDI is seeking a highly experienced, hands-on Senior Process Engineer with expertise in thin-film deposition, plasma-based processing, and advanced materials manufacturing. The ideal candidate will own and lead the development, optimization, and scale-up of GDI's silicon anode roll-to-roll (R2R) deposition technology and play a key role in transitioning our processes from the laboratory to pilot- and large-scale manufacturing systems.The successful candidate will drive process development and innovation, work closely with equipment vendors and manufacturing partners, and help establish stable, repeatable, and scalable deposition processes capable of supporting megawatt-scale silicon production. This is a hands-on, cross-functional role that will work across R&D, equipment development, facility support, and manufacturing operations.The role will also support facility and operational requirements related to process development, equipment installation and commissioning, and day-to-day manufacturing activities, working closely with internal teams, contractors, and external partners. The successful candidate should be comfortable working directly on equipment, troubleshooting process issues in real time, and supporting operations in a manufacturing environment.Roles and Responsibilities:Lead the development and optimization of silicon anode deposition processes, including PECVD or related thin-film technologies.Define scalable process architectures to transition from R&D tools to pilot and manufacturing systems.Develop process recipes, operating windows, and key process parameters for silicon deposition and related process steps.Support the design, installation, commissioning, and qualification of R2R deposition equipment.Work closely with equipment vendors and engineering partners to develop scalable process platforms.Implement robust process controls to ensure reproducibility, reliability, and manufacturing readiness.Collaborate with cell engineering teams to integrate GDI's silicon anodes into next-generation battery architectures.Support facility and operational requirements related to process development, equipment installation, commissioning, and manufacturing operations.Support equipment troubleshooting, process qualification, and continuous improvement activities as GDI moves from R&D toward production.Work with internal teams, contractors, and external partners to identify and resolve process, equipment, facility, and operational issues.Develop and maintain process documentation, specifications, operating procedures, and other technical documentation needed to support scale-up and manufacturing.Required Qualifications:Ph.D. or M.S. in Materials Science, Chemical Engineering, Chemistry, Physics, or a related field. Exceptional candidates with a B.S. and significant relevant industry experience will also be considered.5+ years of experience in process engineering, materials development, or thin-film processing.Strong expertise in thin-film deposition technologies (PECVD, CVD, ALD, or related processes).Demonstrated experience scaling advanced materials processes from R&D to pilot or manufacturing environments.Experience working with advanced energy materials, battery technologies, or semiconductor processing.Experience with experimental design (DOE), data analysis, and process optimization.Familiarity with roll-to-roll or sheet-to-sheet manufacturing processes is a plus.Experience with roll-to-roll manufacturing, particularly thin-film deposition or coating processes, is strongly preferred.Hands-on experience with process equipment, including equipment installation, troubleshooting, commissioning, and qualification.Experience with vacuum systems, plasma processing, gas delivery systems, or related process equipment is preferred.Excellent communication skills with experience collaborating with external partners and cross-functional teams.Behavioral Attributes:Highly independent and self-driven with a passion for hands-on technology development.Strong problem-solving skills and a data-driven approach to process engineering.Comfortable working across lab development, pilot operations, and manufacturing environments.Collaborative team player who thrives in a fast-paced deep-tech startup environment.Motivated by the opportunity to develop technology that will advance the energy storage industry.Location: Rochester, NYTravel: Some travel may be required domestically (up to 10%) and internationally (up to 10%) annually. Total travel will not exceed 20% annually. A valid driver's license and use of a personal vehicle may be required.Compensation: GDI offers competitive market-based compensation, including health insurance coverage and stock options. This is a full-time role suitable for experienced professionals. Range begins at $110,000 annually.Eligibility: Applicants must be legally authorized to work in the United States and have dependable transportation.