Battery Manufacturing Engineer

About Upgrade Energy
Upgrade Energy is building the next generation of ultra-lightweight, high-energy-density lithium-ion battery systems for demanding aerial and robotic applications. We design, build, and manufacture batteries in-house for customers pushing the limits of performance, reliability, and weight.

We are a small, fast-moving company with real customers, real revenue, and hardware shipping today. Our culture values deep technical ownership, speed, and pragmatic engineering over bureaucracy. As the company grows, there is clear opportunity for technical growth, increased responsibility, and leadership for strong performers.

Role Overview
As a Battery Manufacturing Engineer at Upgrade Energy, you will sit at the intersection of design, production, and quality, owning manufacturing process development from prototype builds through low-to-high volume production.

You will be responsible for developing, refining, and scaling manufacturing processes for advanced lithium-ion battery packs using both pouch and cylindrical cells. This is a highly hands-on role where you will spend significant time on the production floor building packs, debugging failures, improving yield, and turning R&D builds into repeatable, documented processes.

You will work closely with our engineering team across electrical, mechanical, and testing, as well as technicians and assemblers, to ensure products are safe, manufacturable, and production-ready.

What You Will Do

• Own manufacturing process development for lithium-ion battery packs from cell to pack
• Translate engineering designs into robust, repeatable assembly processes
• Define build sequences, process flows, tooling needs, and work instructions
• Perform hands-on assembly, integration, and testing of battery packs
• Develop and maintain SOPs, assembly documentation, and travelers
• Lead root cause analysis for manufacturing defects, test failures, or yield loss
• Drive continuous improvement initiatives for quality, throughput, and reliability
• Provide DFM and DFA feedback to electrical and mechanical design engineers
• Support new product introduction from prototype builds to production ramp
• Assist in fixture, jig, and tooling design for welding, alignment, and testing
• Train and support technicians and assemblers on new processes
• Maintain and improve manufacturing equipment including welders, testers, and fixtures
• Partner with quality to define inspection criteria and control plans

Required Qualifications

• Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Manufacturing Engineering, or a related field, or equivalent hands-on experience in battery manufacturing
• Three or more years of experience in manufacturing engineering or advanced battery assembly
• Hands-on experience with lithium-ion battery packs using pouch and or cylindrical cells
• Experience developing manufacturing processes, SOPs, and work instructions
• Ability to read and interpret electrical schematics, mechanical drawings, and BOMs
• Proficiency with lab and production tools such as multimeters, ACIR testers, welders, and crimp tools
• Strong understanding of DC electronics and battery fundamentals
• Demonstrated problem-solving ability and experience with root cause analysis methods such as 5-Why or Fishbone
• Comfort working in a fast-paced environment with evolving requirements

Preferred Qualifications

• Experience with aerospace, drone, or robotics battery systems
• Familiarity with battery management systems and pack integration
• Experience designing or refining fixtures, tooling, or test stations
• Exposure to Lean manufacturing, PFMEA, or continuous improvement methodologies
• Experience supporting production ramp from prototype to volume manufacturing
• Knowledge of battery safety standards or qualification testing

Physical and Work Requirements

• Ability to lift up to 30 pounds
• Ability to stand, sit, and work on the production floor for extended periods
• Ability to distinguish colors and work with fine mechanical details
• This role is on-site in El Segundo, California

Why Upgrade Energy

• Work on real hardware that ships to customers today
• High ownership and visibility with direct impact on product performance
• Flat team structure with close collaboration across engineering and production
• Opportunity to shape manufacturing systems early rather than inherit legacy processes
• Clear opportunity for career growth, expanded technical ownership, and leadership as the company scales
• Competitive compensation based on experience

Job Type: Full-time

Pay: $60,000.00 - $110,000.00 per year

Benefits:

• Professional development assistance

Work Location: In person