Sr. Process Cell Engineer - Formation - Battery Cell Development Center

Description

The Role

The Sr. Process Engineer - Formation will play a key role in launching and scaling formation operations within GM's Battery Cell Development Center (BCDC). This facility serves as a critical link between GM R&D, product development, and high-volume EV battery manufacturing - bridging the gap between lab-scale cell builds and industrialization capable products and processes.

In this role, you will own the implementation, and optimization of formation, degassing, and capacity grading processes. You will translate lab-scale innovations into scalable, robust formation protocols. You will work closely with advanced cell and advanced process engineering, operations, and quality to ensure cells meet performance, safety, and process targets across build campaigns. The ideal candidate brings technical expertise in cell manufacturing and formation.

What You'll Do

Formation Process Development & Optimization

• Optimize charge/discharge sequences, current profiles, rest periods, and temperature profiles for initial cell activation and capacity calibration.
• Define/Refine formation protocol parameters for scale (C-rates, voltage limits, temperature setpoints, voltage plateau criteria, self-discharge limits) to condition cells and establish accept/reject criteria.
• Continuously improve formation throughput and yield - tuning charging rates, minimizing cycle time, and eliminating inconsistencies while avoiding cell damage.
• Design, execute, and analyze Design of Experiments (DoEs) to optimize formation, degassing, and capacity grading cycles.

• Transition lab-scale formation procedures to rate-capable processes.
• Define scalable process parameters (batch sizing, temperature control per batch, automation of process steps) that are directly transferable to gigafactory environments.
• Develop recipes, specifications, and run rules that support repeatable, cost-effective formation at scale.
• Partner with central process engineering and product engineering teams to validate that new cell designs, chemistries, and dimensions can be effectively formed.

• Support Site Acceptance Testing (SAT), commissioning, and qualification of formation equipment.
• Coordinate with maintenance and operations teams to troubleshoot equipment issues promptly, minimizing downtime during formation operations
• Partner with maintenance to develop preventive maintenance protocols, calibration schedules, and equipment specifications to ensure consistent performance and uptime.

• Partner with quality to establish post-formation quality tests (capacity, voltage profile analysis, self-discharge, safety screening) to verify cells meet specifications.
  • Analyze trend formation data (charge capacity, voltage vs. time, temperature) using software tools to detect anomalies, improve yield, and inform process decisions.
  • Establish Process Failure Mode and Effects Analysis (PFMEA) and Statistical Process Control (SPC) methods to ensure consistent, high-quality production.
  • Maintain detailed manufacturing procedures and operating instructions

• Adhere to and champion all GM safety standards, battery safety guidelines, and regulatory requirements when handling cells and performing formation operations.
• Ensure proper use of PPE, safe handling of flammable electrolytes, and adherence to protocols preventing other cell-level hazards.
• Support EHS procedures, audits, and incident investigations related to formation processes.

• Collaborate with electrochemists, battery engineers, manufacturing engineers, quality engineers, and operations to align formation requirements with product development and build schedules.
• Conduct root-cause analysis when cells fail to meet specifications and implement corrective actions.
• Drive continuous improvement by evaluating new formation technologies and methods (e.g., pulse charging, advanced SEI formation techniques) that can improve cell quality or reduce cycle time.
• Scale up lessons learned from the Wallace Battery Cell Innovation Center (WBCIC) into BCDC manufacturing systems.

• BS or higher in Chemical, Mechanical, Electrical, or Materials Engineering.
• 5+ years of experience in battery cell manufacturing or development, with direct involvement in formation, testing, or electrochemical process engineering.
• Deep understanding of lithium-ion cell electrochemistry, including SEI layer formation, voltage/current behaviors, and cell conditioning.
• Experience translating lab-scale processes into scalable processes.
• Proficiency with data analysis tools (Python, Minitab, Excel) for process characterization and optimization.
• Experience with DOE, PFMEA, and SPC methodologies.
• Strong analytical, problem-solving, and troubleshooting skills.
• Hands-on experience with formation equipment, PLC-based controls, and automated test systems.
• Ability to work off-shifts, weekends, or holidays as needed to support build campaigns.
• Travel Requirements: Ability to travel 10% to support new equipment and supplier activities.