Battery Model Development and Analysis Engineer, Ford Energy

Battery Cell Simulation Engineer

Ford Energy is a newly formed, wholly-owned subsidiary of Ford Motor Company dedicated to accelerating U.S. energy independence. Leveraging Ford's century of manufacturing excellence and world-class battery energy storage systems (BESS) technology, Ford Energy designs, manufactures, and services grid-scale and commercial DC battery energy storage systems (BESS). Ford Energy is uniquely positioned to capture the growing demand for reliable, US-built energy storage systems.

We are not just building batteries; we are building the infrastructure for the next generation of the American grid.

In this position...

The Battery Cell Simulation Engineer is responsible for developing and applying advanced electrochemical models (P2D/P4D) to understand battery cell performance, degradation, and lifetime behavior, with direct linkage to system-level life prediction for Battery Energy Storage Systems (BESS). This role builds physics-based cell models to quantify degradation mechanisms and translate them into system-level life simulation inputs, enabling accurate warranty estimation and augmentation strategies.

The position acts as a key bridge between cell-level electrochemistry and BESS system performance, supporting data-driven decisions on durability, reliability, and lifecycle cost optimization.

What you'll do...

• Electrochemical Modeling (Primary Focus)
  • Develop and apply high-fidelity electrochemical models, including P2D/P4D lithium-ion battery models and reduced-order models for system integration.
  • Simulate reaction kinetics and transport phenomena, lithium concentration gradients and over potential, and internal current density and utilization distribution.
  • Evaluate cell capability limits, including power and energy capability, SOC-dependent performance, and rate limitations under different conditions.
• Cell-Level Life & Degradation Modeling
  • Develop physics-based models to predict cell degradation, including SEI growth and side reactions, lithium plating risk and conditions, and loss of active material and impedance growth.
  • Quantify capacity fade and resistance increase over life, and sensitivity to temperature, SOC window, and cycling conditions.
  • Support cell design trade-offs and degradation mitigation strategies.
• Thermal-Electrochemical Coupling
  • Develop coupled electrochemical-thermal models, including heat generation from electrochemical reactions and temperature-dependent kinetics and degradation.
  • Analyze cell temperature gradients and hot spots, and thermal impact on performance and aging.
  • Provide heat generation and degradation sensitivity inputs for system-level modeling.
• Manufacturing Variation & Cell Behavior
  • Incorporate manufacturing-induced variations into cell models, including electrode thickness and loading variation, porosity and density variation from calendaring, and microstructural heterogeneity.
  • Evaluate impact of process variation on performance distribution, and manufacturing defects on degradation and life.
  • Support translation of modeling insights into process control targets and cell consistency and quality improvements.
• System-Level Life Modeling Interface (BESS Integration)
  • Translate cell-level model outputs into system-level inputs for BESS simulations, including degradation rates under varying duty cycles and temperature and usage sensitivities.
  • Support development of system-level life prediction models and duty cycle-based aging simulations.
  • Collaborate with system and CAE teams to ensure consistent model integration and proper scaling from cell to pack to system.
• Warranty Estimation & Augmentation Strategy Support
  • Provide modeling inputs for warranty projections (capacity retention, degradation limits) and performance degradation over service life.
  • Support evaluation of BESS augmentation strategies (e.g., module replacement, capacity add-back) and trade-offs between degradation, performance, and cost.
  • Enable data-driven decisions on lifecycle management and total cost of ownership (TCO).
• Model Calibration & Validation
  • Calibrate models using experimental data, including cycling and aging tests, and EIS, rate capability, and thermal data.
  • Validate performance and degradation predictions vs. test data.
  • Conduct sensitivity analysis, parameter estimation, and uncertainty quantification.
• Cross-Functional Collaboration
  • Work closely with the Ford Battery Modeling Team and BESS system and controls teams.
  • Support external suppliers with model alignment and parameterization.
  • Translate detailed electrochemical insights into system-level engineering decisions.

You'll have...

• Bachelor's degree in Chemical Engineering, Mechanical Engineering, Materials Science, Physics, or related field.
• 3+ years (MS) or 5+ years (BS) of experience in battery modeling or related fields.
• Strong expertise in electrochemical modeling (P2D or equivalent) and lithium-ion battery fundamentals.

Even Better, you may have...

• Master's or PhD in relevant discipline.
• Experience with P2D/P4D electrochemical…