Senior Cell Assembly Engineer Hayward CA

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. To learn more about Blue Current, Inc., visit

The Senior Cell Assembly Engineer is responsible for developing and refining the cell assembly processes at the core of Blue Current's solid‑state battery technology, where the novelty of the cell design and formulation means that innovation is a routine part of the job rather than an exception. This engineer owns the assembly process from receipt of dry electrode rolls through finished cell delivery, defining the tooling requirements that mechanical and equipment engineers build to, and applying a sophisticated quality toolkit (visual inspection, layer alignment and tolerancing, X‑ray imaging, and electrochemical characterization) to ensure that every cell meets defined structural and performance standards.

Working across electrode process, cell engineering, mechanical engineering, and quality teams, the Senior Cell Assembly Engineer is a central integration point where materials, processes, and measurements come together. Success means a cell assembly process that produces high‑quality, well‑characterized cells consistently today, with the process understanding in place to support scale‑up.

• Develops and refines cell assembly processes for solid‑state batteries, including electrode handling and punching, alignment, lamination, stacking multiple layers, sealing pouches and tabs, and delivering finished products to the cell test team
• Defines tooling and fixture requirements for cell assembly operations, working closely with mechanical and equipment engineers to specify, validate, and iterate on tooling that meets process needs
• Characterizes assembly process parameters and their relationship to cell structural and electrochemical outcomes, building the process understanding needed to set specifications and improve yield
• Applies advanced metrology techniques including X‑ray imaging, electrochemical characterization, and electrochemical testing to evaluate assembly quality and diagnose process failures
• Develops and monitors assembly‑stage QA/QC protocols in partnership with the Quality team, including visual inspection criteria, edge alignment and layer tolerancing standards, and acceptance criteria for finished cells
• Leads root cause investigations on assembly defects and cell failures attributable to assembly process, implementing and documenting corrective actions
• Collaborates with electrode process and cell engineering teams to ensure assembly process decisions account for upstream material and electrode constraints and downstream cell performance requirements
• Contributes to scale‑up planning by identifying critical assembly process parameters and tooling requirements that must be addressed on the path to high‑volume manufacturing
• 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

• PhD, MS (with 3+ years of relevant experience), or BS (with 5+ years of relevant experience) in Materials Science, Chemical Engineering, Chemistry, Physics, or a related field, with a focus on batteries or electrochemical devices

• Experience troubleshooting and diagnosing assembly‑related failures using…