Role Summary
The Principal Engineer for Failure Analysis will be responsible for leading the Failure Analysis team as part of the factory quality organization and serve as the subject matter expert for lithium- ion cell analysis. This pivotal role will be responsible for guiding failure investigations, developing and implementing advanced analytical techniques, and driving continuous improvement in the quality and reliability of our battery products. The Principal Failure Analysis Engineer will utilize a deep understanding of lithium- ion cell chemistry, materials science, and electrical characterization to identify root causes of failures and provide actionable recommendations. This role requires strong leadership capabilities, exceptional problem- solving skills, and the ability to collaborate effectively with cross- functional teams
Key Responsibilities
Conduct in- depth failure analysis investigations on cells returned from the field, manufacturing, or internal testing, utilizing techniques such as Scanning Electron Microscopy (SEM), Energy Dispersive X- ray Spectroscopy (EDS), X- ray Diffraction (XRD), Inductively Coupled Plasma (ICP) spectroscopy (e.g., ICP- OES, ICP- MS), Gas Chromatography- Mass Spectrometry (GC- MS), Fourier Transform Infrared Spectroscopy (FTIR), Electrochemical Impedance Spectroscopy (EIS), and other relevant methods.
Collaborate with internal teams (e.g., R&D, Manufacturing, Quality) and external partners to address failure modes and improve product reliability.
Lead and mentor a team of Failure Analysis Engineers, fostering a collaborative and high- performing environment.
Contribute to the development and improvement of internal testing protocols and quality standards.
Ensure the proper maintenance and calibration of laboratory equipment used for failure analysis.
Present failure analysis results and recommendations to cross- functional teams and management.
Develop, validate, and implement advanced destructive and non- destructive analytical techniques for lithium- ion cell failure analysis.
Utilize industry- standard failure analysis methodologies (e.g., 8D, Fishbone diagrams, Fault Tree Analysis) and quality tools (e.g., Statistical Process Control (SPC), Design of Experiments (DOE)) to systematically investigate and resolve issues.
Conduct electrical characterization to understand the electrochemical behavior of cells and identify anomalies related to failure mechanisms.
Perform detailed material characterization of cell components (e.g., electrodes, electrolyte, separator) to identify material degradation, contamination, or manufacturing defects.
Contribute to the training and development of other engineering personnel on failure analysis principles and techniques.
Stay abreast of the latest advancements in lithium- ion battery technology, failure analysis techniques, and industry best practices.
Serve as the primary subject matter expert for failure analysis of lithium- ion cells, providing guidance and expertise to the R&D, Quality, and Manufacturing teams.
Prepare comprehensive failure analysis reports, clearly documenting findings, root causes, and corrective and preventative actions.
