Formation Process Engineer - 3C Battery

Factorial Energy is a pioneering U.S.-based solid-state battery company driving the future of energy storage and electrification. Partnered with global leaders including Mercedes-Benz, Stellantis, Hyundai, and Kia, Factorial is at the forefront of developing next-generation e-mobility platforms for commercial, defense, and consumer applications-spanning electric vehicles (EVs), drones, eVTOL aircraft, power tools, marine systems, robotics, and more. The company has achieved multiple industry firsts, including being the first to power a demonstration vehicle with a global OEM (Mercedes- Benz) which achieved over 1,200 km (749 mi) of range, and the first to earn UN 38.3 certification for automotive-sized lithium-metal solid-state cells, the first to deliver B-samples of automotive-sized solid-state batteries to major OEMs.

The Opportunity

Factorial Energy is seeking a Formation Process Engineer to join our team in our Cheonan, South Korea location. This person will be responsible for the development, optimization, and mass-production support of formation and grading processes for our Silicon Power Cell line. This role covers the full formation lifecycle - from R&D validation through pilot scale-up to high-volume manufacturing - with a focus on silicon anode-specific formation protocol development, SEI stability, and high-rate capability optimization. The ideal candidate brings deep electrochemical engineering expertise, hands-on formation equipment experience, and a data-driven approach to process improvement and yield stabilization.

In this role, you will

• Lead development and optimization of formation protocols for Si-based power cells, including pre-formation, standard formation, and step-charge strategies tailored to silicon anode expansion behavior
• Design and validate formation recipes (charge/discharge C-rates, temperature windows, cutoff conditions) to maximize ICE, SEI film uniformity, and suppress lithium plating risk on high-Si anodes
• Establish capacity grading specifications defining key binning parameters including capacity, DCIR, and self-discharge rate
• Develop product-specific formation programs optimized for high-rate power cell requirements
• Develop formation protocols that account for silicon anode volume expansion during initial lithiation, minimizing mechanical stress and SEI instability
• Collaborate with R&D and electrode teams to correlate formation conditions with Si anode first-cycle efficiency, swelling behavior, and long-term cycle stability
• Identify root causes of formation and grading anomalies and implement CAPA actions
• Apply SPC, DOE, and FMEA methodologies to reduce batch-to-batch variation and improve process capability (Cpk)
• Partner with QA/QE to define inspection standards for the formation segment
• Optimize formation line takt time and OEE, reducing energy consumption per cell and WIP inventory
• Drive process transfers across all development stages: lab bench → pilot line → mass production
• Develop and maintain PM plans for formation equipment to minimize unplanned downtime
• Collaborate with formation cycler suppliers to define equipment specifications
• Lead FAT/SAT acceptance testing for formation equipment and establish OQ/PQ qualification protocols
• Support MES data integration and in-line monitoring for smart manufacturing capabilities

We are looking for people who

• Have 3+ years of hands-on experience in lithium-ion battery formation and grading processes
• Have experience with silicon anode or high-energy-density cell formation preferred
• Have led or substantially contributed to at least one full NPI or mass production ramp-up project
• Have deep understanding of formation fundamentals: SEI formation, gas evolution, lithium deposition suppression, and electrolyte decomposition
• Are familiar with major formation cycler platforms (Neware, Landt, Arbin, Basytec) and can independently troubleshoot equipment faults
• Are proficient in electrochemical testing: EIS, DCIR, self-discharge, and battery analysis software
• Are proficient in DOE, SPC, FMEA, and data analysis tools (JMP, Minitab, Python, or Excel)
• Have experience with MES/ERP data extraction and visualization
• Hold a Bachelor's degree or higher in Chemical Engineering, Materials Science, Electrochemistry, or related field; Master's preferred
• Have experience with Si anode formation protocol development or high-rate power cell formation (preferred)
• Are familiar with consumer battery safety standards (IEC 62133, UL 1642, UN 38.3) (preferred)

Work Location

Cheonan, South Korea

Factorial Energy is an equal opportunity employer that values diversity at all levels. All qualified applicants, regardless of personal characteristics, are encouraged to apply.

To request a reasonable accommodation to complete an application, job interview, and/or to otherwise participate in the hiring process, please contact ([email protected])