Battery Failure Analysis Engineer

Overview

Join our team as a Battery Failure Analysis Engineer, with hands-on responsibility for operating and maintaining a CT scan system used to analyze battery cells, modules, and packs. This role is central to uncovering and interpreting internal defects through advanced imaging, directly supporting root-cause investigations across various battery form factors. You will serve as a technical bridge between cell manufacturing, battery design, and failure analysis, generating actionable insights for design, quality, and validation efforts.

Responsibilities

• Independently operate CT scan equipment for battery cells, modules, and packs, including sample preparation, fixturing, scan parameter selection, and scheduling in a lab environment.
• Interpret 2D and 3D CT images to identify defects such as electrode misalignment, jellyroll deformation, welding issues, foreign material inclusions, electrolyte dry-out, swelling, and mechanical damage.
• Compile clear and detailed failure analysis reports, including annotated images, measurements, and actionable conclusions for cross-functional teams in design, quality, and validation.
• Conduct battery teardowns and complementary failure analysis in dry room or glovebox settings when needed, ensuring adherence to safety protocols.
• Maintain CT system calibration, perform routine troubleshooting, and coordinate with equipment vendors for service or repairs.
• Enforce strict compliance with radiation, laser, and battery safety standards during CT scan operation and handling of potentially hazardous or damaged lithium-ion cells.
• Support battery validation activities by correlating CT imaging results with electrical, mechanical, and abuse testing data.

Minimum Qualifications

• Bachelor’s degree in Materials Science, Mechanical Engineering, Chemical Engineering, or a closely related discipline.
• 5+ years of experience in battery failure analysis, with a deep background in cell design and structure.
• Comprehensive understanding of cell manufacturing processes, including electrode coating, calendaring, winding/stacking, electrolyte filling, and formation cycling.
• Demonstrated experience operating and interpreting results from CT/X-ray inspection systems for battery analysis.
• Advanced training and adherence to safety protocols for both CT system operation and lithium-ion cell handling.

Preferred Qualifications

• 10+ years total experience in battery failure analysis and cell engineering roles, spanning multiple cell chemistries and formats (cylindrical, pouch, prismatic).
• Proficiency in conducting detailed cell teardowns and failure investigations across a range of battery types, including hard-can designs.
• Familiarity with additional analytical techniques, such as SEM/EDS, cross-sectioning, and optical microscopy for root-cause investigations.
• Experience with battery validation, including electrical, thermal, and mechanical abuse testing methodologies.
• Ability to operate independently in a laboratory environment and effectively communicate technical findings to diverse engineering and development teams.