Sr. Manager, Prototype Scaleup

Summary

Blue Current is seeking a highly experienced and hands-on Senior Manager, Early Scaleup to lead the transition of R&D-developed solid-state battery processes into robust, intermediate-scale manufacturing. This role is pivotal in bridging the gap between lab innovation and pilot-line readiness by maturing electrode fabrication and cell assembly processes, defining process windows, and establishing reliable scaled workflows. The ideal candidate combines deep technical expertise with strong operational leadership, driving disciplined execution, rapid iteration, and data-driven decision-making. The candidate will collaborate closely with R&D, Cell Engineering, and Manufacturing teams to accelerate technology readiness and ensure a smooth pathway toward full-scale production.

Key responsibilities

• Lead a team of engineers and technicians responsible for translating new R&D materials, cell designs, and processes into robust, repeatable, and scalable intermediate-scale manufacturing workflows across electrode fabrication and cell assembly.
• Develop and optimize scaled-up electrode processes, including slurry formulation, mixing, tape casting or dry processing, drying, and calendaring, ensuring stable operation, defined process windows, and strong correlation to both R&D and pilot-line requirements.
• Scale cell assembly operations such as electrode punching, stacking or winding, lamination, and formation/conditioning, driving improvements in yield, consistency, and throughput.
• Define and execute scale-up roadmaps, setting clear deliverables, timelines, and success metrics while coordinating resources across equipment, materials, analytical, and manufacturing teams.
• Own equipment strategy for early-scale processes, including specification, vendor selection, installation, commissioning, and validation of semi-automated or small-format tools.
• Establish CTQs, process windows, SOPs, and quality controls to ensure reliable operation and smooth transfer of maturing processes to the pilot line.
• Lead root-cause analyses and structured problem-solving efforts, using DOE, statistical analysis, and failure analysis tools to resolve yield, performance, and equipment-related issues.
• Collaborate closely with R&D, Cell Engineering, Analytical, and Advanced Manufacturing to align process requirements, ensure manufacturability, and maintain tight feedback loops that accelerate technology iteration.
• Build and develop a high-performing engineering and technician team, providing mentorship, technical guidance, and strong operational leadership.
• Champion a strong safety culture, ensuring safe scaling of materials, processes, and equipment while continuously improving safety protocols and training.

 Requirements 

• BS/MS/PhD in Chemical Engineering, Materials Science, Mechanical Engineering, or related discipline, with 8+ years of industry experience in lithium-ion or solid-state battery manufacturing, process engineering, or scale-up.
• Demonstrated expertise in scaling battery processes from lab-scale to pre-pilot or intermediate scale, including slurry mixing, dry processing, drying, calendaring, punching, stacking, winding, lamination, pouching, and formation.
• Hands-on experience with equipment specification, installation, commissioning, and validation, particularly for semi-automated or custom early-scale tools.
• Proven ability to establish process windows, CTQs, SOPs, control plans, and quality metrics that enable reliable and repeatable scaled operations.
• Strong leadership experience, including managing and developing engineering and technician teams in a fast-paced, hardware-centric environment.
• Excellent analytical and problem-solving skills, with proficiency in DOE, statistical analysis, root-cause troubleshooting, and structured problem-solving methodologies.
• Exceptional project management capabilities, including roadmap creation, milestone definition, cross-functional coordination, and on-time delivery of complex technical programs.
• Strong communication and documentation skills, with the ability to work closely with R&D, Equipment Engineering, Cell Engineering, Analytical, and Manufacturing to ensure smooth process handoff and rapid iteration cycles.
• Deep commitment to safety, with experience developing or enforcing safe operating procedures for battery materials, chemicals, and equipment.

Physical Demands and Work Environment

• 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.