Senior Cell Design Engineer

Sion Power Corporation, based in Tucson, AZ, is the leading developer of high-energy rechargeable lithium‑metal battery technology, with more than 20 years of research and development. Years of research and development have yielded the Licerion® lithium metal technology, poised to dramatically change the lithium battery landscape by delivering the highest combination of energy density and specific energy.

This position will develop next-generation cells using advanced materials for automotive, defense, and consumer electronics applications as a key member of the Cell Engineering group. The successful applicant will develop, validate, and commercialize this innovative cell based on state-of-the‑art commercial and proprietary materials. The responsibilities of this position cover cell design, analysis, material development, and support for product launch.

• Lead the planning and execution of lithium metal cell and electrode development with a strong focus on Design for Manufacturability (DFM) and scalability.
• Select, characterize, qualify, and validate cell materials and components, including cathode, anode, electrolyte, separator, and current collectors.
• Cell balancing with proprietary anode, matching cathode, and other key components for high performance cell
• Design, develop, and optimize proprietary anode architectures to achieve high‑performance cell metrics (energy density, cycle life, safety, and cost).
• Define, plan, and execute statistically robust Design of Experiments (DOE) to support cell fabrication, process optimization, and electrochemical testing.
• Analyze experimental and production data to identify performance trends and failure mechanisms; perform root‑cause analysis and implement corrective actions using DFMEA and PFMEA methodologies.
• Develop and maintain detailed technical documentation, including material specifications, design requirements, test protocols, and engineering reports.
• Provide hands‑on engineering support to cell manufacturing teams to resolve yield, quality, and process‑related issues during pilot and production builds.
• Partner with Supply Chain and suppliers to develop, validate, and control material specifications for new and existing materials, and to address supplier‑related quality concerns.
• Support engineering‑level and pilot test builds in collaboration with quality, operations, and manufacturing teams to ensure successful design transfer and scale‑up.

• Master's or PhD in Chemistry, Electrochemistry, Materials Science, Chemical Engineering, or a closely related field.
• Minimum of 10 years of industrial experience in the design, development, and commercialization of lithium rechargeable cells.
• Self‑motivated and accountable engineer with a strong sense of ownership and demonstrated ability to drive continuous improvement initiatives.
• Proven track record of successful design and development of lithium rechargeable cell components, assemblies, and formation processes.
• Hands‑on experience developing and managing technical specifications, component and assembly requirements, and quality tools including DFMEA and 8D problem‑solving.
• Demonstrated expertise in electrochemical characterization techniques, including cyclic voltammetry (CV), electrochemical impedance spectroscopy (EIS), cycle life testing, and abuse testing.
• Working knowledge of statistical analysis and Design of Experiments (DOE); experience with Minitab or similar statistical software preferred.