Staff Battery Cell Reliability & Modeling Engineer

Quick Facts

• Focus: Battery cell reliability improvement for vendor LFP and NMC programs
• Work areas: Ongoing Reliability Testing (ORT), failure modeling, test validation, and transfer of learnings to production

Description

Own ongoing Reliability Testing (ORT) for vendor cell programs (LFP and NMC), including test intent, execution, data review, and supplier escalation. Build electrochemical and mechanical failure-mode models from ORT and accelerated-life data, validate cycle life and other tester methods, and turn model outputs into early-warning metrics for qualification and manufacturing. Translate qualification learnings into production controls and ramp gates.

Responsibilities

• Own ORT protocol, sample plans, and pass/fail criteria aligned with Cell Qualification during the transition from NPI to MP
• Drive containment and root cause when ORT flags capacity fade, impedance growth, swelling, or safety-relevant events
• Model electrochemical failure modes (e.g., SEI, lithium plating, cathode fade, impedance) and mechanical failure modes (e.g., swelling, jelly-roll deformation, can stress)
• Use models to create early-warning metrics and reliability risk assessments for SIE, Qualification, and MP
• Validate tester methods (capacity, DCIR/EIS, thickness/swelling, abuse-adjacent checks) to ensure comparability between supplier and Tesla data
• Review supplier and third-party test packages against Tesla’s cell test intent
• Partner with Cell Qualification on performance (charge capability, energy, lifetime, degradation) and integrate learnings into MP process controls and ramp gates

Requirements

• Degree in electrochemistry, chemical engineering, materials science, mechanical engineering, or related field, or equivalent experience
• Hands-on lithium-ion testing experience, including cycle life, calendar life, and ORT (or equivalent reliability programs)
• Working knowledge of LFP and NMC degradation and failure modes (electrochemical and mechanical)
• Ability to build models or statistical/physics-based predictions from test data using Python, MATLAB, Abaqus, or similar tools
• Experience with cell testers and characterization (capacity, impedance, thickness/swelling) and validating test methods
• Strong written and verbal communication; able to work with Cell Qualification, suppliers, and manufacturing
• Hardware- and data-driven mindset focused on closing the loop from lab results to production control
• Vendor-cell/supplier industrialization background (e.g., incoming cell quality, PPAP-style qualification, or ORT at a cell maker or OEM)
• Structural modeling experience of cells (swelling, can, jelly roll) alongside electrochemistry

Benefits

• Medical plans at day 1 (options with $0 payroll deduction)
• Family-building, fertility, adoption, and surrogacy benefits
• Dental (including orthodontic coverage) and vision plans (options with $0 paycheck contribution)
• Company-paid HSA contribution when enrolled in the High-Deductible medical plan with HSA
• Healthcare and Dependent Care Flexible Spending Accounts (FSA)
• 401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits
• Company-paid Basic Life, AD&D; short-term and long-term disability insurance
• Employee Assistance Program
• Sick and vacation time, paid holidays (flex time for salary positions)
• Backup childcare and parenting support resources
• Voluntary benefits (e.g., critical illness, hospital indemnity, accident insurance, theft & legal services, pet insurance)
• Weight loss and tobacco cessation programs
• Tesla Babies program; commuter benefits; employee discounts and perks
• Earned Wage Access (real-time pay access paid daily), subject to eligibility and schedule