Sr. Materials Engineer, Cell Dry Electrode Development

We are looking for a Senior Cell Materials Engineer to join our electrode development team, focusing on the integration and optimization of next-generation binder systems for dry battery electrode applications. In this role, you will leverage your expertise in polymer science, composite film mechanics, and materials characterization to investigate how binder chemistry, processing conditions, and particle-level interactions govern electrode film formation, mechanical integrity, and electrochemical performance. You will design and execute structured experiments across a range of binder integration approaches, apply rigorous root cause analysis to understand and resolve failure modes at the film and interface level, and use characterization tools including rheology, DMA, tensile and adhesion testing, and electrochemical evaluation, to connect processing decisions to real-world cell performance. This is a hands-on, high-impact role for someone who thinks across scales from molecular interactions and particle surface chemistry up to film mechanics and cycling behavior, and thrives in a fast-moving, cross-functional R&D environment where technical depth and collaborative problem-solving drive meaningful progress towards Tesla's long-term energy storage goals.

• Screen, evaluate, and optimize alternative binder systems for electrode applications, assessing performance across mechanical, thermal, and electrochemical dimensions
• Develop working knowledge across multiple binder integration approaches and understand how integration method affects binder distribution, film morphology, and performance outcomes
• Characterize free-standing electrode films and composite binder systems across a range of mechanical conditions including tensile, peel, adhesion, elongation, and viscoelastic behavior
• Conduct root cause analysis of binder and electrode failure modes including delamination, cracking, cohesive vs. adhesive failure, and capacity fade linked to mechanical degradation
• Connect mechanical characterization results to processing decisions and electrochemical outcomes, understanding what a peel test or DMA sweep reveals about the underlying material and why it matters
• Fabricate and evaluate electrode films using relevant processing routes, including coating, calendaring, and other film formation methods, with attention to how processing parameters affect binder behavior and final electrode properties
• Apply DOE methodology and structured RCA practices to reduce defects, improve process windows, and accelerate development cycles
• Build and test electrochemical cells to evaluate the performance impact of materials and process changes, with fluency in cycling, EIS, rate capability, and DQ/DV analysis
• Collaborate cross-functionally with electrochemical testing, process engineering, and materials characterization teams to design experiments that generate actionable insights
• Support translation of successful laboratory findings toward pilot and manufacturing-relevant processes
  

• Degree in Materials Science, Chemical Engineering, Polymer Science, or equivalent experience
• Hands-on electrode fabrication experience - wet and/or dry - at laboratory, pilot, or industrial scale
• Binder screening and optimization experience: understanding how binder chemistry, loading, and integration method affect mechanical integrity and electrochemical performance
• Mechanical characterization of electrode films or composites including peel, tensile, adhesion, and DMA, with the ability to connect results to processing decisions and performance outcomes
• Demonstrated root cause analysis capability on electrode or composite film failure modes including delamination, cracking, adhesion loss, and capacity fade
• Electrochemical literacy including hands-on experience with cycling, EIS, or equivalent sufficient to connect materials-level observations to cell-level outcomes
• Understanding of polymer thermal and viscoelastic behavior such as Tg, modulus-temperature relationships, and softening behavior sufficient to make informed processing decisions
• Familiarity with multiple binder integration approaches across wet and dry processing routes; dry electrode experience is a strong plus
• Structured experimental design (DOE) and the ability to think across length scales from particle-surface interactions up through composite film mechanics to cell-level failure
• Expertise in polymer melt rheology (twin-screw compounding, extrusion, etc.), powder rheology, and compressibility characterization
  

Along with competitive pay, as a full-time Tesla employee, you are eligible for the following benefits at day 1 of hire:

• Medical plans > plan options with $0 payroll deduction
• Family-building, fertility, adoption and surrogacy benefits
• Dental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contribution
• Company Paid (Health Savings Accounts) 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 (90 day waiting period)
• Employee Assistance Program
• Sick and Vacation time (Flex time for salary positions, Accrued hours for Hourly positions), and Paid Holidays
• Back-up childcare and parenting support resources
• Voluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance
• Weight Loss and Tobacco Cessation Programs
• Tesla Babies program
• Commuter benefits
• Employee discounts and perks program

• Associate Materials Engineer - $82,440 - $123,660/annual salary
• Materials Engineer - $98,640 - $147,960/annual salary
• Sr Materials Engineer - $117,360 - $176,040/annual salary

Pay offered may vary depending on multiple individualized factors, including market location, job-related knowledge, skills, and experience. The total compensation package for this position may also include other elements dependent on the position offered. Details of participation in these benefit plans will be provided if an employee receives an offer of employment.