Sr. Process Engineer

Position Summary

Blue Current is seeking a hands-on Senior Process Engineer for developing formulation and coating processes for next generation separators used in Blue Current’s solid-state batteries. The ideal candidate will have a background in formulation, coating and characterization in the battery or adjacent industry (fuel cell/ solar/ electronic materials, etc). Additional experience in electrochemistry of lithium-ion batteries is a bonus. The Senior Process Engineer will design and conduct experiments for prototyping and characterizing new separator formulations and architectures, and collaborate with the Cell Engineering and Advanced Manufacturing teams for qualifying through cell builds and scaling up to the pilot line. This is a highly cross-functional, hands-on and fast-paced position with a team of scientists and engineers that have a shared passion to change the energy storage landscape.

Essential Functions & Responsibilities

• Develop and test new materials, formulation, mixing and coating processes for separators that enable safe, high energy density solid-state batteries. 
• Characterize slurry and separator quality using rheological, mechanical, imaging and electrochemical techniques, and develop new characterization methods as needed.
• Evaluating novel separator compositions and architectures in solid state cells. Analyze test results to understand the impact of separator properties on cell performance.
• Partner with the Advanced Manufacturing team to transfer mixing and coating processes to manufacturing equipment.
• Clearly communicate complex results to cross-functional teams and senior leadership.
• Work with cross-functional teams ensuring high-quality, on-schedule execution of projects. 
• Continuously survey and interpret literature on solid-state battery materials and architectures, integrating key insights into the company’s technical strategies.
• Contribute to the company's IP portfolio by exploring novel materials, cell designs, and processing approaches that advance solid-state cell performance
• Support a strong safety culture by following and improving laboratory safety practices, demonstrating exemplary experimental techniques, and helping implement best-practice updates.

Minimum Qualifications

Education

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

Experience

• Experience in battery R&D, with a strong focus on lithium-ion or solid-state battery systems
• Hands-on experience developing and scaling slurry-based processes, including mixing, coating, and drying
• Proven experience planning, leading, and executing R&D projects, delivering results on schedule in fast-paced environments
• Demonstrated experience collaborating cross-functionally with cell engineering, materials, and manufacturing teams

Skills & Knowledge

• Strong understanding of separator materials, polymer/inorganic composites, and their role in solid-state or lithium-ion batteries
• Expertise in slurry formulation, rheology, and coating science for thin-film materials
• Familiarity with analytical and characterization tools such as SEM, XRD, TGA, FTIR, DSC, and related techniques
• Experience with electrochemical testing techniques such as EIS, GITT, HPPC, CV, and related methods
• Ability to analyze relationships between material properties, processing conditions, and cell performance
• Strong data analysis and problem-solving skills, with a structured, hypothesis-driven approach
• Excellent communication skills, with the ability to clearly present complex technical findings to cross-functional teams and leadership
• Strong project management, organization, and prioritization skills

Preferred Qualifications

• Direct experience with solid-state battery systems and separator architectures
• Experience transferring processes from lab-scale to pilot or manufacturing-scale equipment
• Track record of innovation through patents, publications, or internal IP contributions

Core Values — Minimum Qualifications

Safety & Security First For employees, customers, and intellectual property

Demonstrated commitment to maintaining a safe and secure work environment, including adherence to workplace safety protocols, data privacy standards, and confidentiality requirements. Proven ability to identify and appropriately escalate potential risks to personnel, customers, or sensitive information.

Trust & Respect Treat everyone with honesty, dignity, and sensitivity. Embrace different perspectives. Be humble.

Demonstrated ability to communicate and collaborate effectively with individuals of diverse backgrounds, perspectives, and working styles. Track record of maintaining professionalism, integrity, and discretion in all workplace interactions.

Ownership & Accountability Take responsibility and action. Set goals and deliver. Don't wait for others.

Demonstrated ability to independently prioritize, execute, and follow through on responsibilities with minimal supervision. Proven track record of setting measurable goals, meeting deadlines, and taking initiative to resolve challenges proactively.

Technical Excellence Always strive for the best solution possible.

Demonstrated commitment to quality and continuous improvement in delivering work product, solutions, and outcomes within area of expertise. Ability to evaluate options critically and apply sound judgment to identify the most effective and scalable solution.

Learn & Be Curious Think outside the box. Always learning.

Demonstrated ability to quickly acquire new skills, tools, or domain knowledge in response to evolving business needs. Proven track record of applying creative or unconventional thinking to solve problems.

Be Resourceful Be hungry, frugal, and flexible. Use what you have. Find a way.

Demonstrated ability to deliver results in resource-constrained environments by maximizing existing tools, processes, and partnerships. Proven ability to adapt and find effective solutions in ambiguous or rapidly changing situations.

Delight Customers Build stronger relationships with internal and external customers.

Demonstrated commitment to understanding and exceeding the needs of internal and/or external customers. Track record of building and maintaining strong, trust-based relationships that drive positive outcomes for all stakeholders.

 

Physical Requirements & Working Conditions

• Required to wear personal protective equipment when applicable. 
• Able to pass a respirator fit test and wear a respirator periodically.
• Able to work in an office, lab, and manufacturing environment with chemicals, moving mechanical parts, and electrical hazards.