Senior Process Development Engineer Jobs in Half Moon Bay, CA

Position Summary

Blue Current is seeking a Senior Process Engineer to join the Technical Operations team, supporting solid-state battery R&D and prototyping operations. This role is responsible for improving process performance (yield, throughput, reproducibility) while owning the development, qualification, troubleshooting, and continuous improvement of key process equipment. The Senior Process Engineer will work cross-functionally to translate evolving process requirements into robust, scalable, and well-controlled operations. This is a high-impact role at the intersection of process engineering and equipment engineering in a fast-paced development environment.

Essential Functions & Responsibilities

• Act as the primary engineering owner for assigned battery R&D equipment (e.g., gloveboxes, slurry mixers, film coaters, cell assembly tools, etc.)
• Manage projects and design experiments to improve and optimize technical processes in the fabrication lab to improve yield, throughput, and consistency
• Establish and track key metrics (yield, variability, cycle time) and drive continuous improvement
• Support specification, evaluation, and procurement of new process equipment
• Partner with vendors and internal teams to modify or develop tools to meet evolving process requirements
• Drive improvements in uptime, throughput, and process capability through equipment enhancements
• Lead structured troubleshooting of process and equipment issues, identifying root causes and implementing corrective actions
• Collaborate cross-functionally to connect process changes to cell performance outcomes
• Develop and maintain SOPs, work instructions, and process documentation for technicians
• Provide technical training and guidance to technicians on new processes and tools
• Develop and improve systems to manage work orders, inventory, and maintenance to track process and equipment performance
• Communicate effectively with R&D scientists, engineers, and technicians to align on priorities and execution
• Identify opportunities to improve safety, throughput, quality, and reliability of lab operations
• Other duties as assigned, consistent with the scope and level of this position

Minimum Qualifications

Education

• Bachelor's degree or higher in Engineering, Materials Science, Chemistry, Physics, or related field

Experience

• 5+ years of experience in process engineering, equipment engineering, or manufacturing engineering in a relevant field (e.g., batteries, semiconductors, coatings, thin films)
• Demonstrated ownership of both process optimization and equipment performance
• Experience with equipment specification, commissioning, and qualification

Skills & Knowledge

• Experience with fabrication processes such as coating, mixing, calendering, or similar
• Experience with DOE, data analysis, and process optimization methodologies
• Strong troubleshooting and root cause analysis skills across process and equipment
• Ability to define equipment requirements and translate process needs into technical specifications
• Strong collaboration and communication skills across engineering and operations teams
• Familiarity with safety practices, including chemical handling and engineering controls

Preferred Qualifications

• Direct experience with battery fabrication processes and equipment
• Familiarity with statistical tools or programming (e.g., Python, JMP)
• Experience in R&D, pilot line, or early-stage manufacturing environments

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

• Ability to perform precise manual tasks while standing at a glovebox for extended periods (up to 8 hours per day)
• Must possess the fine motor skills and hand-eye coordination required to manipulate tools and materials through integrated gloves/sleeves.
• Ability to maintain a standing or slightly leaned position for long durations, including reaching and extending arms within the glovebox environment.
• Ability to lift, carry, and maneuver equipment or materials weighing up to 25 lbs occasionally
• Work is performed in a standard R&D laboratory environment
• Core hours are adaptable, though increased availability may be required during peak periods.