Lead Engineer — Substrate

Job description

About the role EnerVenue is seeking a technically strong Lead Engineer — Substrate to own nickel and iron foam substrate specification, qualification, and manufacturing integration for its Aqueous Metal Cell (AMC) platform. The porous metal foam substrate is the structural scaffold for both the cathode and anode — its pore architecture, surface density, and alloy composition directly govern how much active material can be loaded and how well the finished electrode performs over 30,000+ cycles. The successful candidate will own the substrate technical roadmap end-to-end — from foam specification and production-route selection, through incoming qualification, to converting and in-line quality control at the Changzhou facility — working closely with the Head of Cathode Development and Head of Anode Development. This role sits at the intersection of porous metal materials science, electrodeposition/sintering process engineering, and manufacturing, and requires someone equally comfortable in a lab characterizing foam morphology and on a factory floor debugging a slitting or foam-forming line. What you'll do Substrate Engineering & Qualification • Lead specification, qualification, and continuous improvement of nickel foam and iron foam substrates used across EnerVenue's cathode and anode electrode systems • Define and control foam specifications: pore size, PPI (pores per inch), porosity, surface density, ligament thickness, and alloy composition • Evaluate and qualify foam production routes — electrodeposition, chemical vapor deposition (CVD), and sintering — for both nickel and iron foam substrates • Optimize foam morphology and pore architecture to maximize active material loading and adhesion for both cathode (nickel hydroxide) and anode (Ni-Mo plated) applications • Drive substrate contribution to cell-level performance and manufacturability targets: active material retention, mechanical integrity, conductivity, and cycle life • Establish substrate characterization protocols: SEM/porosimetry, pore-size distribution, BET surface area, tap/surface density, tensile and compressive strength, and electrical conductivity • Own substrate-related failure analysis (active material shedding, foam collapse, non-uniform coating) and drive corrective actions with Cathode, Anode, and Manufacturing teams Manufacturing & Supplier Integration (Changzhou, China) • Support commissioning of foam converting and handling operations at the facility — slitting, cutting, cleaning, and inline inspection — from spec to production-qualified output • Qualify and manage relationships with domestic Chinese nickel foam and iron foam suppliers, and equipment vendors where EnerVenue produces foam in-house • Establish incoming-material inspection, SPC, and inline quality monitoring for foam stock used in electrode manufacturing • Work with Manufacturing Engineering to resolve substrate-related yield issues during electrode coating and cell assembly ramp • Ensure substrate sourcing, processing, and handling meet relevant environmental, health, and safety standards under China's GB and MEP regulations Technical Leadership & Cross-Functional Collaboration • Serve as the internal technical authority on porous metal foam substrates and their role in electrode performance • Partner closely with the Head of Cathode Development and Head of Anode Development to co-optimize substrate specification against each electrode's active material and process requirements • Collaborate with the Stanford-based R&D team to translate lab-scale substrate research into manufacturable, qualified production materials • Mentor and, as the team scales, help build out a small substrate engineering team in Changzhou • Report to the Head of Electrode Engineering; provide regular updates on substrate roadmap, qualification status, and supply risk Qualifications Education • Master's or Ph.D. in Materials Science, Metallurgical Engineering, Chemical Engineering, or a closely related field • Equivalent industry experience (4+ years) with a strong portfolio of porous metal foam or substrate product development will be considered in lieu of an advanced degree Core Technical Experience (Non-Negotiable) • Demonstrated expertise in porous metal foam development and manufacturing, including specifying and/or producing nickel foam or iron foam via electrodeposition, CVD, or sintering routes • Working understanding of PPI, porosity, surface density, ligament/pore morphology, and how these parameters relate to electrode active material loading and adhesion • Hands-on experience characterizing porous metal substrates: SEM/porosimetry, BET surface area, pore-size distribution, and mechanical (tensile/compressive) testing • Prior experience supplying or qualifying foam substrates for battery electrodes (cathode and/or anode) in NiMH, alkaline, or metal-hydrogen battery systems • Track record of taking a foam substrate from lab-scale or supplier sample to qualified, high-volume production use Manufacturing & Operations Experience • Experience supporting or commissioning foam converting, cleaning, or forming operations in an industrial setting • Familiarity with Chinese manufacturing supply chains and nickel/iron foam material vendors • Understanding of EHS compliance relevant to foam processing (electrodeposition, sintering, or CVD) under Chinese regulations • Experience working cross-functionally with electrode (cathode and anode) engineering teams Language & Location • Professional working proficiency in Mandarin Chinese required (technical documents, supplier negotiations, team coordination) • Professional proficiency in English required (communication with Silicon Valley HQ, technical reporting) • Based in or willing to relocate to Changzhou, Jiangsu Province, China Preferred Qualifications • Direct experience with nickel-hydrogen or NiMH battery substrate systems • Publications or patents in porous metal foam manufacturing, foam electrodeposition, or sintered metal substrate engineering • Experience with iron-nickel foam substrates as electrode scaffolds • Familiarity with water electrolysis (alkaline or PEM) electrode substrate technology • Experience with DoE (design of experiments) methodologies for foam process optimization • Network within the Chinese nickel/iron foam and porous metals supply chain About EnerVenue, Inc. Named one of the world’s Top Greentech Companies by TIME in 2024 and 2025, EnerVenue builds simple, safer, and flexible energy storage solutions for the clean energy revolution. Based on technology proven over decades under the most extreme conditions, EnerVenue offers a differentiated stationary storage solution that improves upon today’s alternatives. Commercialized from research completed at Stanford University and backed by well-funded investors, EnerVenue is redefining the stationary storage market.