Director New Cell Prototyping

📍 Job Overview

Job Title: Director New Cell Prototyping
Company: Forge Nano
Location: Thornton, Colorado, United States
Job Type: Full-Time
Category: Operations Management / Engineering / R&D Transition
Date Posted: 2025-09-29
Experience Level: 10+ Years
Remote Status: On-site

🚀 Role Summary

• Lead the strategic and operational transition of advanced cell designs from Research & Development (R&D) into robust prototype production lines, ensuring seamless integration of novel materials and innovative designs.
• Drive operational excellence by overseeing the day-to-day execution of prototype manufacturing, focusing on yield, capacity, and continuous improvement initiatives within the energy storage sector.
• Foster critical cross-functional collaboration between R&D scientists, electrode and assembly specialists, and operations teams to translate complex cell architectures into manufacturable and scalable prototypes.
• Implement and manage key performance indicators (KPIs) and a performance dashboard for the prototype line, providing clear reporting on status, risks, and key learnings to senior leadership.
• Ensure the prototype line operates efficiently and compliantly, adhering to ISO 9001 standards through the co-development and review of Standard Operating Procedures (SOPs) and documentation.

📝 Enhancement Note: This role is positioned at a senior level, bridging the gap between cutting-edge R&D and tangible prototype output. It requires a strong blend of technical depth in battery materials and cell engineering, coupled with proven leadership in operational management and process optimization within a manufacturing context. The focus on "New Cell Prototyping" indicates a critical role in accelerating technology validation and de-risking future product development.

📈 Primary Responsibilities

• Translate R&D design priorities into actionable production plans, detailed timelines, and measurable milestones for prototype cell manufacturing.
• Serve as the primary liaison between R&D scientists and the operations team, facilitating the effective conversion of cell designs into reproducible prototype cells.
• Collaborate with electrode (anode/cathode) and assembly leads to refine and optimize existing process improvements and develop new protocols for prototype builds.
• Evaluate and assess prototype equipment needs, prepare comprehensive justifications, and recommend capital expenditure (CapEx) purchases to the VP of Energy Storage.
• Directly supervise the Prototype Line Operations Manager, ensuring efficient and effective day-to-day execution of all prototype manufacturing activities.
• Review and analyze key prototype line performance metrics, including yield, capacity, and Corrective Action Reports (CARs), and guide the implementation of necessary corrective actions.
• Conduct regular meetings with the Operations Manager to gain insights into operational challenges, provide strategic direction, and resolve critical issues impacting production.
• Co-develop, review, and approve SOPs and essential documentation with the Operations Manager to ensure and maintain adherence to ISO 9001 compliance standards.
• Define, implement, and track quarterly KPIs for the prototype line, maintaining a comprehensive performance dashboard for management review.
• Prepare and deliver clear, concise reports on prototype status, identified risks, and critical lessons learned to the VP of Energy Storage.
• Coordinate effectively across R&D, Engineering, and Operations teams to ensure alignment on project goals, resource allocation, and overall project timelines.
• Act as a key bridge between engineering and operations stakeholders to ensure smooth and efficient project execution from concept to prototype delivery.
• Partner closely with the Project Manager to meticulously track project deliverables, key milestones, and resource utilization for prototype development initiatives.

📝 Enhancement Note: The responsibilities emphasize a hands-on leadership approach within a manufacturing operations setting. The role requires not only strategic oversight but also a deep understanding of production processes, equipment justification, and compliance frameworks like ISO 9001, all within the context of accelerating battery technology development.

🎓 Skills & Qualifications

Education:

• Ph.D. or Master of Science (M.S.) in Materials Science, Chemistry, Chemical Engineering, or a closely related scientific or engineering discipline.

Experience:

• A minimum of 10 years of progressive experience specifically in the field of lithium-ion battery or next-generation battery prototyping and scale-up operations.
• Proven track record of successfully leading and managing multidisciplinary technical and operational teams.
• Demonstrated success in transitioning new technologies or product designs from R&D through to prototype manufacturing stages.

Required Skills:

• Advanced technical understanding of electrode materials (anode and cathode), cell architecture (e.g., pouch, cylindrical, prismatic), and battery production workflows.
• Expertise in process improvement methodologies and their application to manufacturing environments, with a focus on yield enhancement and reproducibility.
• Strong leadership and people management abilities, with a capacity to mentor, develop, and empower technical and operational staff.
• Proficient in developing and implementing Standard Operating Procedures (SOPs) and maintaining robust documentation systems for manufacturing quality.
• Familiarity with quality management systems, particularly ISO 9001, including auditing and compliance requirements.
• Excellent organizational, planning, and project management skills with a focus on timeline adherence and resource management.
• Superior problem-solving capabilities, with a data-driven approach to root cause analysis and corrective action implementation.
• Effective communication and interpersonal skills, essential for interfacing between R&D, engineering, and operations teams, as well as reporting to senior management.

Preferred Skills:

• Experience with nano-scale coating technologies relevant to battery materials.
• Hands-on experience with battery prototyping equipment (e.g., coating machines, calendering, slitting, winding, assembly, formation, testing equipment).
• Knowledge of statistical process control (SPC) and design of experiments (DOE) for process optimization.
• Experience with project management software and tools for tracking complex R&D to production transitions.
• Familiarity with hazardous chemical handling protocols and laboratory safety management systems.

📝 Enhancement Note: The qualification requirements highlight a need for deep technical expertise in battery technology combined with significant leadership and operational management experience. The emphasis on both R&D transition and prototype production indicates a role that requires bridging scientific innovation with manufacturing realities.

📊 Process & Systems Portfolio Requirements

Portfolio Essentials:

• Demonstrated experience in translating complex scientific concepts into practical, manufacturable processes within a prototype production environment.
• Evidence of leading process improvement initiatives that resulted in measurable enhancements in yield, throughput, or quality of manufactured components or products.
• Examples of system implementation or optimization within a manufacturing or laboratory setting, showcasing an understanding of workflow design and efficiency.
• Case studies or project summaries that illustrate the successful scale-up of a technology or product from R&D stages to a functional prototype or pilot line.

Process Documentation:

• Experience in developing, documenting, and implementing Standard Operating Procedures (SOPs) for manufacturing processes, particularly within regulated or quality-conscious environments (e.g., ISO 9001).
• Ability to design and document workflows that ensure reproducibility, traceability, and adherence to quality standards in prototype cell manufacturing.
• Proficiency in creating process documentation that supports training, operational consistency, and continuous improvement efforts.

📝 Enhancement Note: While a formal portfolio might not be explicitly requested, candidates will be expected to articulate their experience through detailed descriptions of past projects, processes developed, and operational improvements achieved. This section focuses on the types of evidence that would strongly support an application for this role, emphasizing practical application of process knowledge and documentation skills.

💵 Compensation & Benefits

Salary Range:

• $120,000 - $160,000 per year. Forge Nano may adjust this compensation range based on the candidate's overall skill level, experience, and qualifications.

Benefits:

• Comprehensive Medical, Dental, and Vision insurance plans.
• Disability and Life Insurance coverage.
• Paid Holidays and Paid Time Off (PTO).
• Flexible Spending Account (FSA) options.
• Potential for an annual cash Bonus, performance-dependent.
• 401(k) retirement savings plan with employer match.

Working Hours:

• Standard full-time hours are expected, likely around 40 hours per week, with the understanding that the demands of leading prototype development and operations may require flexibility and occasional extended hours to meet project deadlines and address urgent operational needs.

📝 Enhancement Note: The salary range is competitive for a Director-level position requiring specialized technical expertise and significant leadership experience in the battery industry. The benefits package is comprehensive, standard for full-time roles in the US, and includes performance-based incentives like a bonus and a 401(k) with an employer match, which are attractive to experienced professionals.

🎯 Team & Company Context

🏢 Company Culture

Industry: Advanced Materials Manufacturing, specifically focused on nano-scale coatings and their application in energy storage solutions, particularly lithium-ion batteries. Forge Nano is at the forefront of innovation in this sector, leveraging proprietary technologies to enhance material performance. Company Size: [Forge Nano's company size is not provided in the input, but typical for a growing materials science company in this niche could range from 50-250 employees.]
Founded: [Forge Nano's founding date is not provided in the input. However, as a "fast-growing materials company," it suggests a relatively modern establishment, likely within the last 5-15 years, indicating a dynamic and evolving operational landscape.]

Team Structure:

• The Director of New Cell Prototyping will lead and supervise the Prototype Line Operations Manager, who in turn manages the day-to-day operations.
• This role reports to the VP of Energy Storage, indicating a strategic position within the energy storage division.
• Close collaboration is expected with R&D scientists, electrode and assembly leads, and a Project Manager, highlighting a matrixed or project-based team structure.

Methodology:

• Data-driven decision-making is emphasized, with a focus on reviewing line performance metrics, implementing KPIs, and maintaining performance dashboards.
• Process optimization and continuous improvement are core to the role, evident in the responsibility for refining processes, developing SOPs, and ensuring ISO 9001 compliance.
• A blend of strategic planning (converting R&D priorities into actionable plans) and hands-on operational oversight is required.

Company Website: https://forge-nano.breezy.hr

📝 Enhancement Note: The company operates in a highly innovative and technical field. The culture likely values scientific rigor, problem-solving, and a proactive approach to scaling new technologies. As a fast-growing company, there's an expectation of agility and adaptability within its operational frameworks.

📈 Career & Growth Analysis

Operations Career Level: This role represents a senior leadership position within the operations and engineering function, specifically focused on the critical phase of turning R&D innovations into tangible, testable prototypes. It requires a blend of technical specialization and management expertise. Reporting Structure: The Director reports directly to the VP of Energy Storage, signifying high visibility and strategic importance. This direct line to senior leadership suggests opportunities for significant influence on the company's technology roadmap and operational strategy. Operations Impact: The Director's success directly impacts Forge Nano's ability to validate new battery technologies rapidly and cost-effectively. By ensuring efficient prototype production, this role accelerates the feedback loop to R&D, de-risks future manufacturing scale-up, and ultimately contributes to bringing next-generation energy storage solutions to market faster.

Growth Opportunities:

• Technical Specialization: Potential to deepen expertise in emerging battery chemistries and nano-material applications within an innovation-driven company.
• Leadership Advancement: Opportunity to grow into broader operational leadership roles, potentially overseeing larger manufacturing or scale-up initiatives as the company expands.
• Strategic Influence: Ability to shape the company's approach to prototype development and manufacturing scale-up, influencing long-term product strategy and operational infrastructure.
• Cross-Functional Expertise: Developing a strong understanding of R&D, engineering, project management, and compliance, creating a well-rounded operational leader.

📝 Enhancement Note: This is a pivotal role for individuals looking to make a significant impact in the rapidly evolving battery technology sector. The growth potential is tied to the company's expansion and the successful commercialization of its innovations, offering a clear path for career advancement within operations and engineering leadership.

🌐 Work Environment

Office Type: The role is primarily based in a wet chemical laboratory within a larger production facility. This indicates a hands-on environment where scientific experimentation and manufacturing processes converge. Office Location(s): Thornton, Colorado. This location likely offers access to a skilled workforce in the engineering and manufacturing sectors.

Workspace Context:

• The work environment involves routine handling of hazardous chemicals, necessitating strict adherence to safety protocols and consistent use of Personal Protective Equipment (PPE) such as gloves, eye protection, and lab coats.
• Employees may be required to wear respirators, which involves passing medical evaluations and fit tests, underscoring the commitment to safety in potentially hazardous conditions.
• The environment includes proximity to moving mechanical parts and moderate noise levels typical of a production facility.
• Opportunities for collaboration exist within the prototype line team, with R&D, and with project management, fostering a dynamic and interactive work setting.

Work Schedule:

• While standard full-time hours (approximately 40 per week) are the baseline, the nature of prototype development and operational oversight may necessitate flexibility. Urgent issues, critical experiments, or project deadlines could require extended hours or adjusted schedules to ensure operational continuity and project success.

📝 Enhancement Note: The description clearly outlines a demanding but controlled laboratory and production environment. Candidates should be comfortable with hands-on work, potential hazards, and the need for rigorous safety compliance. The collaborative aspect is key, suggesting a team-oriented approach is vital.

📄 Application & Portfolio Review Process

Interview Process:

• Initial Screening: A review of resumes and applications to assess alignment with the required Ph.D./M.S. and 10+ years of battery prototyping experience.
• Technical Interview: In-depth discussion with hiring managers and/or senior technical leads (e.g., VP of Energy Storage, R&D Scientists) focusing on battery cell design, materials science, prototyping processes, and scale-up challenges. Expect questions related to specific materials, cell architectures, and troubleshooting common issues.
• Operations & Leadership Interview: Evaluation of leadership capabilities, operational management experience, process optimization approach, and ability to manage teams and drive performance metrics. This may involve behavioral questions assessing problem-solving, decision-making under pressure, and cross-functional collaboration.
• Case Study/Presentation (Potential): Candidates may be asked to present on a past project demonstrating their ability to transition R&D to prototype production, highlighting challenges, solutions, and outcomes. This could involve a review of process improvements or operational strategies they implemented.
• Final Interview: Discussion with senior leadership to assess cultural fit, strategic alignment, and overall suitability for the Director role.

Portfolio Review Tips:

• Highlight Transition Successes: Focus on projects where you successfully moved a technology from R&D conceptualization to a functional prototype or pilot line. Quantify achievements wherever possible (e.g., "reduced cycle time by X%", "improved yield by Y%", "delivered Z prototypes ahead of schedule").
• Demonstrate Process Optimization: Showcase examples of how you identified process bottlenecks or inefficiencies and implemented solutions that led to measurable improvements in yield, quality, or throughput.
• Showcase Leadership & Team Building: Provide examples of how you have led, mentored, and developed technical and operational teams, fostering a culture of performance and continuous improvement.
• Document Quality & Compliance: Include details on your experience with quality systems like ISO 9001, SOP development, and ensuring compliance in a manufacturing or laboratory setting.
• Technical Depth: Be prepared to discuss the intricacies of battery materials, electrode design, cell assembly, and characterization techniques at a detailed level.

Challenge Preparation:

• Operational Scenario: Be ready to discuss how you would approach a hypothetical scenario, such as a significant drop in prototype yield or a delay in a critical project milestone. Focus on your systematic problem-solving methodology.
• Process Improvement Proposal: Prepare to outline how you would assess and improve the efficiency of a prototype line, considering equipment, materials, personnel, and workflow.
• Stakeholder Management: Anticipate questions about how you would manage differing priorities between R&D and Operations, or how you would communicate complex technical issues to non-technical stakeholders.

📝 Enhancement Note: The interview process is designed to rigorously assess both technical depth and leadership capabilities. Preparing specific examples of past achievements, particularly those demonstrating successful transitions from R&D to production and process optimization, will be crucial. A strong understanding of battery manufacturing processes and quality systems is essential.

🛠 Tools & Technology Stack

Primary Tools:

• Battery Prototyping Equipment: Familiarity with various stages of battery cell prototyping, including but not limited to:
  • Electrode Manufacturing: Slurry mixers, coater machines (e.g., slot-die, comma coating), calender machines, slitters.
  • Cell Assembly: Winding machines, tab welding, pouch cell formation, can sealing, dry room operations.
  • Testing & Characterization: Battery cyclers (e.g., Arbin, Maccor), potentiostats, environmental chambers, automated test equipment (ATE).
• Laboratory Information Management Systems (LIMS): For tracking samples, experiments, and results within a laboratory setting.
• Process Control Software: Potentially used for monitoring and controlling specific manufacturing equipment or processes.

Analytics & Reporting:

• Data Analysis Software: Proficiency in tools for analyzing experimental and production data (e.g., Excel advanced features, Python with libraries like Pandas/NumPy, MATLAB).
• Statistical Software: Experience with tools for statistical analysis, Design of Experiments (DOE), and Statistical Process Control (SPC) (e.g., JMP, Minitab).
• Dashboarding Tools: Experience in creating and maintaining performance dashboards using tools like Tableau, Power BI, or in-house solutions to visualize KPIs and operational metrics.

CRM & Automation:

• ERP Systems: Familiarity with Enterprise Resource Planning systems for managing supply chain, inventory, and production planning, though direct management might not be required, understanding its integration is beneficial.
• Project Management Software: Tools like Asana, Jira, Microsoft Project, or similar for tracking project timelines, deliverables, and resource allocation.

📝 Enhancement Note: While specific software isn't listed, the role demands deep familiarity with the equipment and processes inherent to battery cell prototyping and manufacturing. Proficiency in data analysis and visualization tools is critical for performance tracking and decision-making. Experience with quality management systems like ISO 9001 implies a need for robust documentation and process control tools.

👥 Team Culture & Values

Operations Values:

• Innovation & Agility: Embracing new material science and engineering concepts while rapidly translating them into functional prototypes. The company's fast-growing nature implies a need for adaptability and quick iteration.
• Quality & Compliance: A strong commitment to maintaining high standards in manufacturing processes, evidenced by the ISO 9001 requirement and the emphasis on SOPs and documentation.
• Data-Driven Decision Making: Utilizing performance metrics, KPIs, and rigorous analysis to guide operational improvements and strategic choices.
• Collaboration & Teamwork: Fostering a highly integrated environment where R&D, engineering, and operations work seamlessly to achieve common goals.
• Safety First: Prioritizing a safe working environment, especially given the handling of hazardous chemicals and operation of complex machinery.

Collaboration Style:

• Cross-Functional Integration: The role acts as a central hub, requiring constant communication and collaboration between diverse teams (R&D, Engineering, Operations, Project Management).
• Feedback Loops: Encouraging open communication for process reviews and constructive feedback to drive continuous improvement in prototype development and production.
• Knowledge Sharing: Promoting the sharing of insights and lessons learned from prototype runs to inform future R&D and manufacturing strategies.

📝 Enhancement Note: The culture at Forge Nano, particularly within its energy storage division, likely emphasizes a forward-thinking, technically driven, and safety-conscious approach. Success in this role hinges on the ability to foster collaboration across disciplines and drive operational excellence while pushing the boundaries of battery technology.

⚡ Challenges & Growth Opportunities

Challenges:

• Bridging R&D to Production: Navigating the inherent complexities and potential disconnects between laboratory-scale R&D and pilot-scale prototype production. This involves managing expectations, adapting processes, and ensuring reproducibility.
• Rapid Technology Evolution: Staying abreast of the fast-paced advancements in battery materials, cell chemistries, and manufacturing techniques to ensure prototype capabilities remain cutting-edge.
• Resource Management: Balancing competing priorities, limited prototype line capacity, and potential equipment constraints while meeting aggressive timelines for technology validation.
• Safety & Compliance: Maintaining rigorous safety standards and ISO 9001 compliance in a dynamic laboratory and production environment with hazardous materials.

Learning & Development Opportunities:

• Cutting-Edge Technology Exposure: Deep immersion in the development of next-generation battery technologies and nano-scale materials.
• Operational Leadership Growth: Developing advanced skills in managing manufacturing operations, leading technical teams, and optimizing production processes in a high-growth environment.
• Strategic Impact: Gaining experience in influencing company strategy through successful technology validation and de-risking of future products.
• Industry Networking: Opportunities to engage with leading researchers, engineers, and manufacturers in the battery and advanced materials sectors.

📝 Enhancement Note: This role presents significant challenges that are balanced by substantial opportunities for professional growth and impact. Successfully navigating these challenges will provide a unique skill set and a strong platform for future leadership roles in the energy sector.

💡 Interview Preparation

Strategy Questions:

• Transitioning R&D to Prototype: "Describe a complex R&D project you successfully transitioned into prototype production. What were the key challenges, and how did you overcome them? What metrics did you use to define success?"
  • Preparation: Have a specific case study ready. Focus on your methodology for translating scientific requirements into manufacturing processes, risk mitigation, and stakeholder alignment.
• Operational Improvement: "Imagine our prototype line yield drops by 15% unexpectedly. What steps would you take to diagnose and resolve the issue?"
  • Preparation: Outline a systematic approach: data collection, root cause analysis (e.g., fishbone diagram, 5 Whys), involving relevant teams, implementing corrective actions, and monitoring results.
• Team Leadership: "How do you motivate and develop a team of highly technical individuals, especially when facing tight deadlines or setbacks?"
  • Preparation: Discuss your leadership philosophy, methods for setting clear expectations, providing feedback, fostering a collaborative environment, and empowering team members.

Company & Culture Questions:

• Company Vision: "What excites you most about Forge Nano's mission and its role in the future of energy storage?"
  • Preparation: Research Forge Nano's specific technologies, market position, and recent news. Connect your passion for battery technology and materials science to their goals.
• Operations Culture: "How would you foster a culture of safety and continuous improvement within the prototype operations team?"
  • Preparation: Emphasize your commitment to safety protocols, your approach to encouraging proactive problem-solving, and how you'd integrate feedback into process improvements.
• Impact Measurement: "How do you measure the success and impact of a prototyping operation on the broader business objectives?"
  • Preparation: Discuss KPIs related to speed-to-validation, cost-effectiveness of prototypes, quality of data generated, and contribution to de-risking commercialization.

Portfolio Presentation Strategy:

• Structure Your Narrative: For any project you present, follow a clear structure: Problem/Opportunity -> Your Role & Actions -> Solutions Implemented -> Results & Impact (quantified where possible).
• Focus on Process & Optimization: Highlight specific process improvements you designed or implemented, detailing the methodology and the resulting efficiency gains or quality enhancements.
• Demonstrate Technical Acumen: Be prepared to discuss the scientific and engineering principles behind your work, especially concerning battery materials and cell construction.
• Showcase Leadership: Weave in examples of how you led teams, managed stakeholders, and drove alignment to achieve project goals.
• Tailor to Forge Nano: If possible, connect your past experiences and insights to Forge Nano's specific technologies and challenges in battery prototyping.

📝 Enhancement Note: Interview preparation should focus on articulating concrete examples that demonstrate both deep technical expertise in battery prototyping and strong operational leadership. Quantifiable results and a structured approach to problem-solving will be key differentiators.

📌 Application Steps

To apply for this Director New Cell Prototyping position:

• Submit your application through the Forge Nano careers portal linked via Breezy HR.
• Tailor your Resume: Highlight your 10+ years of experience in battery prototyping and scale-up, emphasizing leadership roles, technical achievements in electrode design, cell architecture, and process optimization. Integrate keywords such as "lithium-ion," "next-gen batteries," "prototype production," "ISO 9001," and "SOP development."
• Prepare Your Narrative: Develop a compelling story around your most significant achievements in transitioning R&D to prototype production, focusing on quantifiable results and your role in process improvement and team leadership.
• Research Forge Nano: Understand their specific technologies, market position, and company values to articulate your enthusiasm and alignment during interviews.
• Anticipate Technical Questions: Review fundamental concepts in materials science, chemistry, chemical engineering, and battery manufacturing processes to be ready for in-depth technical discussions.

⚠️ Important Notice: This enhanced job description includes AI-generated insights and operations industry-standard assumptions. All details should be verified directly with the hiring organization before making application decisions.

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