Senior Process Development Engineer ; Particle Size Control Thornton

Senior Process Development Engineer I (Particle Size Control)

Thornton, CO

Solid Power is seeking a Senior Process Development Engineer to join our team working to revolutionize the battery industry through the development of next‑generation, all solid‑state rechargeable batteries. This position is part of the Electrolyte Systems Engineering team focused on developing new powder processes and scaling up to mass production. The Process Development Engineer will be responsible for process development and design to produce high‑quality solid electrolytes, specializing in particle size control technology.

• Work with cross‑functional teams to scale up prototype materials into pilot and production scale equipment.
• Own process development and experimental planning for particle size control technology.
• Independently plan, execute, and analyze design of experiments and effectively communicate results to targeted and broader audiences.
• Identify, test, and implement new equipment in the electrolyte manufacturing process.
• Utilize SCADA and batch record information to determine critical process parameters.
• Apply statistical programs such as Minitab or JMP to determine if data sets are statistically different or similar.
• Support the equipment validation and product qualification process.
• Participate in process FMEA’s and quality gate reviews during the development process.
• Lead and assist in the process hazard analysis (PHA). Identify and implement layers of production to ensure process safety.
• Develop work instructions for equipment and process operations.
• Assist EH&S in ensuring occupational safety on the manufacturing floor.

• Bachelor’s degree or higher in Chemical Engineering or a related field of study.
• Minimum 8 years of experience in process development including scale up, continuous improvement, and equipment commissioning preferably in chemical manufacturing.
• Strong knowledge of particle size control techniques and particle size measurement techniques.
• Strong process development & engineering skills (process data analysis, scale up technology, root cause analysis, DOE).
• Experience in powder handling processes including transfer, milling and classification.
• Proficiency in statistics software packages (JMP, Minitab) and process simulation tools.
• Hands‑on experience working with hazardous and flammable materials.
• General knowledge of OSHA standards, international fire code, electrical area classification, and EPA requirements.
• Interpersonal skills for developing positive working relations with other employees.
• Willingness to execute multiple tasks in a fast‑paced start‑up environment.

• Required to wear Personal Protective Equipment (PPE) as necessary including eye protection, hair net, gloves, face mask, coveralls, full‑face respirator or PAPR.

$100,000 - $145,000 per year.

Solid Power offers a comprehensive benefit package that includes medical, dental and vision insurance, employer‑paid Life/AD&D/STD/LTD insurance, a 401(k) plan with company match, 8 paid holidays plus the week between Christmas and New Year’s off, unlimited PTO, up to six weeks paid FMLA leave, cell phone reimbursement, and eligibility to participate in our bonus and equity plans.

This position could require access to technology, software and other information that is subject to governmental access control restrictions due to export controls. Employment is conditioned on the continued availability of government authorization, including an export license or other required documentation. The company reserves the right to delay commencement, rescind an offer, terminate employment, or modify job responsibilities, compensation, benefits, or access to facilities and information systems to maintain compliance with applicable government access control restrictions.

Solid Power is an equal‑opportunity employer. We do not discriminate on the basis of any protected group status under any applicable law. We welcome applicants of all backgrounds and encourage diversity on our team.