Director of Process Development
Coreshell Technologies, Inc., San Leandro, California, United States, 94579
Position: Director of Process Development
Reports To: EVP of Battery Manufacturing & Commercialization
Coreshell's metallurgical Silicon anode technology delivers high capacity, fast-charging, and superior safety. Our low-cost liquid-phase nano-coating addresses critical electrode-surface degradation issues and enables batteries with a Silicon-dominant anode that have higher energy density, superior intrinsic thermal safety, and significantly lower cost/kWh compared to current LIBs. Our Si anode material is lower than the cost of graphite and 100% domestically sourced. We strive to transform the global automotive market by enabling low-cost and long-range EVs as a first step towards net-zero sustainability in the near future.
Position Summary As the Director of Process Development, you will lead the hands‑on development, optimization, and validation of battery manufacturing processes across electrode fabrication, cell assembly, and formation at the pilot and production scale. This individual will develop, optimize, and scale the battery manufacturing process to ensure high quality throughput, ensuring process stability and improving yield. The ideal candidate will be a strong technical leader with direct experience working in scaling and optimizing battery manufacturing production.
Reporting to the EVP of Manufacturing and Commercialization, this role focuses on translating cell designs and performance targets—developed in collaboration with Cell Development—into robust and statistically controlled manufacturing processes. You will provide system-level ownership of process quality, ensuring that process development outcomes evolve into scalable and auditable production‑ready processes.
Core Responsibilities 1. End-to-End Process Development Ownership
Lead process development across electrode fabrication (mixing, coating, calendaring), cell assembly, and formation/aging/testing
Translate cell design intent and performance targets into manufacturable, scalable, and controllable process conditions
Lead and govern scientifically grounded DOE strategies across all process development teams and identify statistically significant CTPs (Critical-to-Process parameters)
Translate DOE results into defined process windows and control plans enabling sustained quality, reproducibility, and process capability
Partner with production teams to embed CTPs into systematic monitoring and change‑control processes
Identify opportunities to improve productivity, decrease costs, increase throughput, improve reproducibility and deliver cells in accordance with project timelines
2. Process Risk Management & Failure Mitigation
Own and implement Process FMEA (PFMEA) across electrode, assembly, and formation processes and identify and mitigate process risks
Apply Fault Tree Analysis (FTA) to trace system-level cell failures (e.g., gas generation, impedance growth, voltage drift, yield loss) to specific process, material, or equipment contributors
Ensure PFMEA and FTA outputs are consistently reflected in cell design priorities, process changes, and control strategies
3. Cross-Functional Integration and team leadership
Work closely with Cell Development to ensure consistency between electrochemical design and process execution, and also work closely with Production & Equipment teams to ensure developed processes are manufacturable
Through hands-on leading, provide technical direction, prioritization to electrode, assembly, and formation process team leads
Establish consistent standards for documentation, data integrity, and technical decision-making across process development teams
Required Experience & Qualifications
Bachelor’s degree in Mechanical, Electrical, Chemical Engineering, or a related field (Master’s degree or PhD a plus, not required)
7+ years of experience in lithium-ion battery process development, scaling up, and improving yield, and maintaining high quality standards
Demonstrated success scaling processes from pilot to production environments
Proven experience PFMEA, DOE-based process development, CTP definition and control plans
Strong understanding of process interactions across electrode, assembly, and formation
Experience with prismatic or cylindrical cell formats preferred
Employment: Full-time
Compensation: $170,000 – $195,000 base salary (salary and equity dependent on experience)
Applications are reviewed on a rolling basis.
If you are a U.S. veteran, you may identify yourself as such.
If you have a disability, you may self-identify to help us track diversity.
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Reports To: EVP of Battery Manufacturing & Commercialization
Coreshell's metallurgical Silicon anode technology delivers high capacity, fast-charging, and superior safety. Our low-cost liquid-phase nano-coating addresses critical electrode-surface degradation issues and enables batteries with a Silicon-dominant anode that have higher energy density, superior intrinsic thermal safety, and significantly lower cost/kWh compared to current LIBs. Our Si anode material is lower than the cost of graphite and 100% domestically sourced. We strive to transform the global automotive market by enabling low-cost and long-range EVs as a first step towards net-zero sustainability in the near future.
Position Summary As the Director of Process Development, you will lead the hands‑on development, optimization, and validation of battery manufacturing processes across electrode fabrication, cell assembly, and formation at the pilot and production scale. This individual will develop, optimize, and scale the battery manufacturing process to ensure high quality throughput, ensuring process stability and improving yield. The ideal candidate will be a strong technical leader with direct experience working in scaling and optimizing battery manufacturing production.
Reporting to the EVP of Manufacturing and Commercialization, this role focuses on translating cell designs and performance targets—developed in collaboration with Cell Development—into robust and statistically controlled manufacturing processes. You will provide system-level ownership of process quality, ensuring that process development outcomes evolve into scalable and auditable production‑ready processes.
Core Responsibilities 1. End-to-End Process Development Ownership
Lead process development across electrode fabrication (mixing, coating, calendaring), cell assembly, and formation/aging/testing
Translate cell design intent and performance targets into manufacturable, scalable, and controllable process conditions
Lead and govern scientifically grounded DOE strategies across all process development teams and identify statistically significant CTPs (Critical-to-Process parameters)
Translate DOE results into defined process windows and control plans enabling sustained quality, reproducibility, and process capability
Partner with production teams to embed CTPs into systematic monitoring and change‑control processes
Identify opportunities to improve productivity, decrease costs, increase throughput, improve reproducibility and deliver cells in accordance with project timelines
2. Process Risk Management & Failure Mitigation
Own and implement Process FMEA (PFMEA) across electrode, assembly, and formation processes and identify and mitigate process risks
Apply Fault Tree Analysis (FTA) to trace system-level cell failures (e.g., gas generation, impedance growth, voltage drift, yield loss) to specific process, material, or equipment contributors
Ensure PFMEA and FTA outputs are consistently reflected in cell design priorities, process changes, and control strategies
3. Cross-Functional Integration and team leadership
Work closely with Cell Development to ensure consistency between electrochemical design and process execution, and also work closely with Production & Equipment teams to ensure developed processes are manufacturable
Through hands-on leading, provide technical direction, prioritization to electrode, assembly, and formation process team leads
Establish consistent standards for documentation, data integrity, and technical decision-making across process development teams
Required Experience & Qualifications
Bachelor’s degree in Mechanical, Electrical, Chemical Engineering, or a related field (Master’s degree or PhD a plus, not required)
7+ years of experience in lithium-ion battery process development, scaling up, and improving yield, and maintaining high quality standards
Demonstrated success scaling processes from pilot to production environments
Proven experience PFMEA, DOE-based process development, CTP definition and control plans
Strong understanding of process interactions across electrode, assembly, and formation
Experience with prismatic or cylindrical cell formats preferred
Employment: Full-time
Compensation: $170,000 – $195,000 base salary (salary and equity dependent on experience)
Applications are reviewed on a rolling basis.
If you are a U.S. veteran, you may identify yourself as such.
If you have a disability, you may self-identify to help us track diversity.
#J-18808-Ljbffr