Principal Engineer – Cell Design & Mechanical Architecture

About Ens"

Ensurge Micropower (OSE: ENSU) is developing next-generation solid-state microbatteries using advanced thin-film and semiconductor-compatible manufacturing technologies. Our technology platform combines thin-film materials, precision patterning, multilayer stacking, and advanced cell architectures to enable high-performance rechargeable batteries for demanding applications.

We are seeking a Principal Engineer - Cell Design & Mechanical Architecture to lead the design and development of our next-generation microbattery cells. This is a highly hands-on technical leadership role for an engineer who can translate cell requirements into cell architecture, mechanical design, CAD models, mask sets, stacking concepts, and manufacturable designs. The ideal candidate understands both the design requirements and the manufacturing processes well enough to make intelligent design-for-manufacturing decisions.

The Principal Engineer will be the technical owner for cell architecture, mechanical design, CAD, mask-set design, and stacking architecture. The role will work closely with materials, thin-film process engineering, manufacturing, equipment engineering, and product development to ensure that cell designs are not only technically sound but also manufacturable, scalable, and capable of achieving the required performance and yield. The ideal candidate is a hands-on engineer who enjoys solving multidisciplinary problems and can move from concept to CAD to mask design to prototype to assembly to testing to design iteration.

• Lead the mechanical and structural design of solid-state microbattery cells and multilayer cell architectures.
• Develop multiple cell design concepts and evaluate trade-offs between energy density, performance, manufacturability, reliability, yield, and cost.
• Define cell dimensions, layer structures, interfaces, tolerances, alignment requirements, and mechanical constraints.
• Develop detailed 3D CAD models, drawings, assemblies, and engineering specifications.
• Apply GD&T and design-for-manufacturing principles to precision microbattery components and assemblies.
• Analyze mechanical stresses, dimensional variation, thermal expansion, layer interfaces, and other factors affecting cell reliability.
• Establish design rules and standards for future cell generations.

• Own mask-set design and layout development for microbattery fabrication.
• Translate cell architecture into mask layouts and manufacturing patterns.
• Define critical dimensions, alignment tolerances, registration requirements, and design constraints.
• Collaborate with internal and external mask/fabrication partners.
• Review mask designs for manufacturability and process compatibility.
• Drive design iterations based on process capability, yield, and cell performance.

• Develop multilayer stacking concepts and assembly strategies.
• Define layer sequence, alignment strategy, interfaces, registration requirements, and mechanical constraints.
• Work closely with process engineering to develop robust stacking processes.
• Identify and resolve defects associated with misalignment, layer damage, particles, mechanical stress, and interface failures.
• Develop design features that improve assembly yield and process robustness.

• Work closely with process engineers to ensure cell designs are compatible with sputtering, patterning, cutting, stacking, and assembly processes.
• Define design tolerances based on actual process capability.
• Identify design changes that improve manufacturing yield and repeatability.
• Participate in process capability studies and design-of-experiment activities.
• Establish feedback loops between manufacturing data and cell design.

• Lead engineering builds and prototype cell design iterations.
• Analyze cell performance and failure modes and translate findings into design improvements.
• Work with characterization and electrochemical teams to correlate cell design with performance.
• Develop design verification plans and acceptance criteria.
• Support root-cause analysis of mechanical and cell-level failures.

• Se…