Process Scale Up Engineer Jobs in Santa Clara, CA

Position Summary

The Staff Electrode Process Engineer plays a key role in developing, optimizing, and scaling electrode manufacturing processes at Blue Current, helping advance electrode fabrication from pilot production toward higher-volume manufacturing. Working closely with cell engineering, quality, and manufacturing teams, this position leads process development initiatives, evaluates equipment and process improvements, and resolves complex technical challenges that impact product quality, process capability, and manufacturability. The Staff Electrode Process Engineer provides technical leadership in electrode processing, contributes to scale-up efforts, and helps establish robust, scalable manufacturing methods that support the company's growth and future production needs.

Essential Functions & Responsibilities

• Leads the development and execution of electrode process improvement and scale-up plans, providing technical input on process design, equipment selection, and manufacturing approaches across mixing, coating, drying, and calendering operations
• Establishes process specifications, critical parameter ranges, and qualification criteria that serve as the technical standard against which current and future electrode manufacturing operations are evaluated
• Leads the development and implementation of QA/QC systems in partnership with the Quality team, setting the measurement philosophy and acceptance standards that govern finished electrode quality
• Drives process scale-up efforts, identifying the technical and equipment gaps between current pilot-scale capabilities and gigafactory-level production requirements, and defining the work needed to close them
• Engages directly with equipment vendors and external process contractors, defining technical requirements, evaluating proposals, and holding external parties accountable to deliverables that serve Blue Current's manufacturing strategy
• Synthesizes process development findings into clear technical recommendations for senior management and executives, framing complex tradeoffs in terms of cost, risk, timeline, and scalability
• Works across cell engineering, quality, and advanced manufacturing teams to ensure electrode process decisions are made with full visibility into upstream material constraints and downstream cell assembly requirements
• Mentors junior and mid-level process engineers in experimental design, equipment operation, process characterization, and structured problem-solving
• Leads projects by developing clear, actionable plans with defined milestones and success metrics, managing timelines effectively, and ensuring high-quality, on-schedule execution
• Supports a strong safety culture by following and improving laboratory safety practices, demonstrating exemplary experimental techniques, and helping implement best-practice updates
• Other duties as assigned, consistent with the scope and level of this position

Minimum Qualifications

Education

• PhD (with 3+ years of relevant experience), Master's (with 6+ years of relevant experience), Bachelor's (with 8+ years of relevant experience) in Chemical Engineering, Materials Science, Chemistry, or a related field, or equivalent combination of education and industry experience

Experience

• Hands-on experience developing and optimizing slurry-based electrode manufacturing processes across mixing, coating, drying, and calendering operations
• Track record of selecting, validating, and qualifying process equipment with working knowledge of multiple mixer and coater types across varying process requirements
• Experience defining process specifications and QA/QC protocols, including critical parameter identification, measurement method selection, and acceptance criteria
• Experience leading cross-functional technical work and communicating findings and recommendations to senior stakeholders

Skills & Knowledge

• Deep working knowledge of slurry rheology and how mixing and coating process parameters influence electrode microstructure and final properties
• Proficiency with statistical methods for process characterization and control, including design of experiments and statistical process control
• Proficiency with standard data analysis tools sufficient to process, visualize, and communicate process and quality data

Certifications / Licenses

• N/A

Preferred Qualifications

• Prior experience owning a process scale-up program from pilot through high-volume production, including making independent technology selection decisions with significant capital or strategic implications
• Experience architecting or leading the implementation of a QA/QC or MES system across a manufacturing organization, rather than operating within an existing one
• Deep familiarity with solid-state or dry electrode manufacturing processes, including independent evaluation of emerging coating or mixing technologies for potential adoption
• Experience serving as the primary technical interface with capital equipment vendors during facility build-out or major equipment procurement cycles
• Background applying Six Sigma or similar methodologies at a program leadership level, including training or certifying others

Core Values - Minimum Qualifications

Safety & Security First

For 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.

Trust & Respect

Treat everyone with honesty, dignity, and sensitivity. Embrace different perspectives. Be humble.

• Demonstrated ability to communicate and collaborate effectively with individuals of diverse backgrounds, perspectives, and working styles.
• Track record of maintaining professionalism, integrity, and discretion in all workplace interactions.

Ownership & Accountability

Take responsibility and action. Set goals and deliver. Don't wait for others.

• Demonstrated ability to independently prioritize, execute, and follow through on responsibilities with minimal supervision.
• Proven track record of setting measurable goals, meeting deadlines, and taking initiative to resolve challenges proactively.

Technical Excellence

Always strive for the best solution possible.

• Demonstrated commitment to quality and continuous improvement in delivering work product, solutions, and outcomes within area of expertise.
• Ability to evaluate options critically and apply sound judgment to identify the most effective and scalable solution.

Learn & Be Curious

Think outside the box. Always learning.

• Demonstrated ability to quickly acquire new skills, tools, or domain knowledge in response to evolving business needs.
• Proven track record of applying creative or unconventional thinking to solve problems.

Be Resourceful

Be hungry, frugal, and flexible. Use what you have. Find a way.

• Demonstrated ability to deliver results in resource-constrained environments by maximizing existing tools, processes, and partnerships.
• Proven ability to adapt and find effective solutions in ambiguous or rapidly changing situations.

Delight Customers

Build 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.

Physical Requirements & Working Conditions

• Able to pass a respirator fit test and wear a respirator periodically.
• Regularly works in an active manufacturing and laboratory environment; standing and walking for a significant portion of the workday (approximately 4-6 hours per day)
• Frequent interaction with process equipment, requiring manual dexterity and the ability to make detailed visual inspections of materials and coated electrodes
• Occasional lifting of items up to 30 lbs (e.g., material containers, equipment components)
• Prolonged periods of screen-based work for data analysis, documentation, vendor communication, and executive reporting
• Regular use of personal protective equipment (PPE) including safety glasses, gloves, and lab coat; additional PPE may be required depending on materials handled
• Exposure to industrial solvents, electrode materials, and other chemical substances; adherence to all applicable safety protocols and handling procedures is required
• Travel estimated at 10-15% of working time, primarily domestic, reflecting increased vendor engagement and external partner coordination relative to junior roles
• Standard weekday business hours; occasional off-hours availability may be required during critical process runs, equipment installations, or qualification events