Director of Process Development at Coreshell Technologies

San Leandro, California, United States -

Full Time

Start Date

Immediate

Expiry Date

21 May, 26

Salary

195000.0

Posted On

20 Feb, 26

Experience

5 year(s) or above

Remote Job

Yes

Telecommute

Yes

Sponsor Visa

Skills

Process Development, Electrode Fabrication, Cell Assembly, Formation, Process Optimization, Process Validation, DOE Strategies, PFMEA, FTA, Scale-Up, Process Control, Yield Improvement, Throughput Increase, Lithium-Ion Battery, Prismatic Cell, Cylindrical Cell

Industry

Nanotechnology Research

Description

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 Location & Benefits Location: San Leandro, CA Employment: Full-time Compensation: $170,000 – $195,000 base salary (salary and equity dependent on experience) Benefits: Medical, dental, vision, 401(k) Applications are reviewed on a rolling basis.

Responsibilities

This role involves leading the end-to-end development, optimization, and validation of battery manufacturing processes across electrode fabrication, cell assembly, and formation at pilot and production scales. Key duties include translating cell design targets into robust, statistically controlled manufacturing processes and owning process quality through systematic monitoring and change control.