Staff Battery Engineer

Staff Battery Engineer

Job Summary:

The Battery Manufacturing Engineer will provide critical engineering support to ensure efficient, high-quality production of battery modules and pack assemblies. This role partners closely with design, procurement, quality assurance, and assembly teams to translate engineered designs into manufacturable assemblies, optimize production processes, and support new product development. The Battery Manufacturing Engineer will define assembly documentation, establish work instructions, develop and improve manufacturing processes, and help train personnel to ensure consistent quality, safety, and efficiency.

Responsibilities and Duties: 

• Primary responsibility is to provide engineering support for the company's battery manufacturing

• Serve as Battery Subject Matter Expert (SME) across all projects relating to Lithium-Ion battery pack manufacturing

• Develop and maintain assembly documentation to maintain high quality standards in our products 

• Develop and integrate battery handling safety standards throughout manufacturing process and ensure that assembly processes clearly identify any potential safety hazards minimize safety risks  

• Collaborate closely with the design team to define cell selection, pack configuration, and system integration to ensure that “Design for Manufacture” principals and methods are utilized in the design of new products 

• Collaborate with design team to support the development of battery system qualification and certification plans

• Define process parameters for welding, joining, and bonding operations for battery modules.

• Lead the development and execution of comprehensive in-process test plans and procedures for battery modules and battery packs designed for aerospace applications   

• Help train assembly personnel in running battery testing equipment (e.g., cyclers, environmental chambers, safety test equipment) and data acquisition systems.

• Make improvements throughout the assembly process which will reduce cost, reduce variation, or improve reliability 

• Define line layout to optimize production workflow and throughput

• Develop jigs and fixtures to aid in production quality and reduce waste

• Utilize lean 6 sigma principles to reduce non-conformances and improve process efficiency and quality

• Make sure that assembly processes clearly identify any potential safety hazards, and design processes and fixtures which will minimize safety risks  

• Support failure analysis, root cause investigations, and corrective actions for battery performance issues.

• Help define/develop assembly aids/fixtures to increase efficiency and quality 

Required Qualifications and Skills: 

• Bachelor's degree in manufacturing or mechanical engineering 

• This position requires a minimum of 10+ years of experience in battery manufacturing engineering.  

• Experience with BMS design, integration and operation.

• Understanding of battery electrochemistry, performance characteristics, and safety requirements for lithium-ion batteries.

• Knowledge of battery safety, environmental, and reliability testing as per industry standards.

• Hands-on experience in a manufacturing environment is necessary.  

• Ability to extract manufacturing information from a computerized inventory control system 

• Knowledge of transitioning battery prototypes into production builds  

• Must be able to work in a small, effective manufacturing team 

• Knowledge to translate an engineered design into build instructions which can be used by assembly and test personnel to duplicate the required product performance 

• Ability to determine cost effective and reliable means of assembly in an electronics environment 

• Take responsibility for establishing and maintaining assembly documentation 

• Ability to comprehend specification sheets 

• Familiarity with windows based personal computers 

• Must be able to work with a minimum of supervision 

Desired Qualifications and Skills: 

• Graduate Degree in Electrical Engineering, Mechanical Engineering, Manufacturing Engineering, or Industrial Engineering

• Understanding of UN38.3, NAVSEA S9310 and/or equivalent (UL, IEC) battery safety standards

• Additional experience working with new product developments.   

• Familiarity with electronics manufacturing. 

• Specific experience with sheet metal fabrication, plastics, and printed circuit board manufacture.   

• Knowledge of computerized MRP/ERP systems, an understanding of inventory control methods and production control techniques. 

• Experience with supplier management and procurement (such as SOWs, RFPs, and/or vendor management) 

• Knowledge of Lean Principles 

Comprehensive Benefits & Perks:    

• Health & Wellness: Choose from three health, dental, and vision plans - including a 100% employer-paid option covering both employees and their families.    

• Paid Time Off: Enjoy 120 hours of PTO, 80 hours accrued plus an additional 40 hours of holiday break pay in addition to Christmas Eve, Christmas Day, and New Year’s Day off.    

• Life Insurance: $25,000 employer-paid life insurance policy, with the option to purchase additional coverage for employees and their families.    

• Supplemental Coverage: Access optional benefits such as Critical Illness, Hospital Indemnity, Accident Insurance, and Critical Illness with Skin Cancer coverage.    

• Health Savings Account (HSA): Take advantage of a tax-advantaged HSA to manage medical expenses.    

• Retirement Savings: 401(k) with a company match to support your financial future.    

• Paid Holidays: Enjoy 9 paid holidays throughout the year.    

• Work Environment: A casual dress code, complimentary snacks, and a welcoming company culture.    

• Ideal Location: Work in an area that offers an outstanding quality of life - a perfect place to live, work, and play!    

Company Overview:    

Empirical Systems Aerospace, Inc (ESAero) is a leader in aerospace engineering, product development, and manufacturing, dedicated to delivering high-quality, innovative, and cost-effective solutions to the industry. We specialize in cutting-edge system design, rapid product development, precision manufacturing, comprehensive testing, and technology demonstrations to support the evolving needs of the aerospace community. Committed to excellence, on-time delivery, and continuous growth, we invest in infrastructure to expand our manufacturing and aftermarket capabilities while maintaining the highest standards of engineering services.    

At ESAero, we don’t just build products, we engineer solutions that propel 

the aerospace industry forward. 

This position is fully on-site at ESAero in San Luis Obispo, CA 

ESAero is an equal opportunity employer.      

E-Verify participation required for employment.      

All ESAero positions require US citizenship or US resident status.          

Must be able to pass background check and drug test.        

Hiring Range: $ 130k-$170k Salary/Exempt    

Location: Santa Maria, CA   

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